SEN05475-01

WHEEL LOADER

WA1200 -6
SERIAL NUMBERS

60001

and up

Notice of revision

Notice of revision
1th. revision The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list below. 2011/10
Mark Q q () Indication Page to be newly added Page to be replaced Page to be deleted Action required Add Replace Discard

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SEN0537702-00

0 -1

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

0-1

Machine model
WA1200-6

Serial number
60001 and up

00 Index and foreword

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WA1200-6

00-1

Table of Contents

Table of Contents
00 Index and foreword Table of contents .................................................................................................................... Table of contents ................................................................................................................. Foreword and general information .......................................................................................... Safety notice ........................................................................................................................ How to read the shop manual .............................................................................................. Explanation of terms for maintenance standard .................................................................. Handling of hydraulic components....................................................................................... Method of disconnecting and connecting push-pull type coupler ........................................ Handling of electric equipment............................................................................................. How to read electric wire code............................................................................................. Precautions when performing work...................................................................................... Standard tightening torque table.......................................................................................... List of abbreviation............................................................................................................... Conversion table .................................................................................................................. 01 Specification Specification............................................................................................................................ Specification dimension drawing.......................................................................................... Specifications....................................................................................................................... Weight table ......................................................................................................................... Table of fuel, coolant and lubricants .................................................................................... 10 Structure and function Engine and cooling system ..................................................................................................... Damper ................................................................................................................................ Cooling system .................................................................................................................... Cooling fan motor................................................................................................................. Power train.............................................................................................................................. Power train........................................................................................................................... Hydraulic piping drawing of torque converter and transmission .......................................... Torque converter.................................................................................................................. Main relief valve and torque converter relief valve............................................................... Torque converter regulator valve ......................................................................................... ECMV................................................................................................................................... Transmission........................................................................................................................ Transmission control valve .................................................................................................. Transmission lubricating oil relief valve ............................................................................... Transfer................................................................................................................................ Torque converter oil cooler .................................................................................................. Center support ..................................................................................................................... Axle ...................................................................................................................................... Final drive ............................................................................................................................ Steering system ...................................................................................................................... Steering equipment layout drawing...................................................................................... AJSS .................................................................................................................................... Steering pump...................................................................................................................... Switch pump ........................................................................................................................ Steering demand valve ........................................................................................................ Rotary valve ......................................................................................................................... EPC valve (for steering)....................................................................................................... 00-2 00 00 0000000000000000000000002 2 16 16 21 23 25 27 30 40 43 46 50 54

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Table of Contents

Diverter valve....................................................................................................................... Emergency steering relief valve........................................................................................... Steering lock valve............................................................................................................... Brake system .......................................................................................................................... Brake equipment layout drawing ......................................................................................... Brake valve .......................................................................................................................... Charge valve........................................................................................................................ Accumulator (for brake) ....................................................................................................... Slack adjuster ...................................................................................................................... Brake ................................................................................................................................... Parking brake....................................................................................................................... Parking brake solenoid valve............................................................................................... Emergency parking brake release valve.............................................................................. Check valve of parking brake circuit .................................................................................... Undercarriage and frame ........................................................................................................ Axle mount........................................................................................................................... Center hinge pin .................................................................................................................. Jack-up point ....................................................................................................................... Hydraulic system .................................................................................................................... Hydraulic piping layout drawing ........................................................................................... Work equipment control lever linkage.................................................................................. Hydraulic tank ...................................................................................................................... Work equipment pump No.1 ................................................................................................ Work equipment pump No.2 ................................................................................................ EPC valve (for work equipment) .......................................................................................... Neutral cutoff solenoid valve (NC valve).............................................................................. Relief valve .......................................................................................................................... Accumulator (for EPC valve) ............................................................................................... Work equipment control valve ............................................................................................. Work equipment...................................................................................................................... Work equipment linkage ...................................................................................................... Electrical system ..................................................................................................................... Machine monitor system...................................................................................................... Multi-function monitor .......................................................................................................... Work equipment and AJSS control system ......................................................................... Work equipment control lever .............................................................................................. Transmission control system ............................................................................................... Engine starting circuit .......................................................................................................... Engine stopping circuit......................................................................................................... Electric parking brake control .............................................................................................. Sensor .................................................................................................................................

10- 103 10- 106 10- 107 10- 108 10- 108 10- 109 10- 115 10- 119 10- 120 10- 122 10- 123 10- 124 10- 125 10- 126 10- 129 10- 129 10- 131 10- 132 10- 133 10- 133 10- 135 10- 136 10- 139 10- 152 10- 175 10- 177 10- 179 10- 180 10- 181 10- 194 10- 194 10- 196 10- 196 10- 224 10- 277 10- 312 10- 315 10- 341 10- 343 10- 347 10- 357

20 Standard value table Standard value table ............................................................................................................... 20Standard value table for engine........................................................................................... 20Standard value table for chassis.......................................................................................... 2030 Testing and adjusting Tool for testing, adjusting and troubleshooting ....................................................................... Tools for testing, adjusting, and troubleshooting ................................................................. Safety precautions to follow before starting work ................................................................ Engine and cooling system ..................................................................................................... Testing engine speed .......................................................................................................... Testing exhaust gas color.................................................................................................... WA1200-6

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30- 4 30- 4 30- 9 30- 13 30- 13 30- 15 00-3

Table of Contents

Testing blow-by pressure..................................................................................................... Measuring engine oil pressure............................................................................................. Measuring exhaust gas temperature ................................................................................... Testing intake air pressure (boost pressure) ....................................................................... Testing radiator performance............................................................................................... Measuring wind speed across radiator and oil cooler.......................................................... Testing and adjusting fan belt tension ................................................................................. Testing and adjusting air conditioner compressor belt tension ............................................ Power train.............................................................................................................................. Adjusting speed sensor........................................................................................................ Testing and adjusting torque converter and transmission oil pressure................................ Traction control function checking procedure ...................................................................... Testing torque converter oil cooler performance ................................................................. Testing additional cooler fan speed ..................................................................................... Flushing procedure for torque converter and transmission circuit ....................................... Retrieval of disabled machine due to transmission valve failure ......................................... How to measure play of center hinge bearing ..................................................................... Measuring wear of rear axle support ................................................................................... Steering system ...................................................................................................................... Testing and adjusting steering oil pressure ......................................................................... Testing and adjusting emergency steering oil pressure....................................................... Bleeding air from steering circuit.......................................................................................... Testing and adjusting steering stopper bolt ......................................................................... Adjusting steering follow-up linkage..................................................................................... Testing steering EPC valve.................................................................................................. Testing and adjusting steering surge cut valve oil pressure ................................................ Testing and adjusting steering main relief valve oil pressure .............................................. Testing rotary valve output pressure.................................................................................... Brake system .......................................................................................................................... Testing brake performance .................................................................................................. Testing lowering of wheel brake oil pressure....................................................................... Testing of slack adjuster ...................................................................................................... Mesuring wear of wheel brake disc...................................................................................... Testing and adjusting accumulator charge pressure ........................................................... Testing brake accumulator oil pressure leakage ................................................................. Testing emergency parking brake valve oil leakage amount ............................................... Testing brake valve oil leakage amount............................................................................... Testing brake cooling oil pressure ....................................................................................... Testing brake oil cooler performance................................................................................... Testing parking brake performance ..................................................................................... Testing wear of parking brake disc ...................................................................................... Method of releasing parking brake manually ....................................................................... Testing parking brake oil pressure....................................................................................... Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ......................................................................................................................... Hydraulic system..................................................................................................................... Testing and adjusting work equipment oil pressure by using multi monitor......................... Testing and adjusting work equipment oil pressure by using oil pressure gauge................ Testing and adjusting work equipment PPC oil pressure .................................................... Measuring point of hydraulic pump oil pressure .................................................................. Testing and adjusting PV control relief valve oil pressure ................................................... Testing and adjusting differential valve output oil pressure ................................................. Testing work pump ES valve output pressure ..................................................................... Testing and adjusting work pump CO (cut-off) valve oil pressure ....................................... 00-4

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30- 80 30- 86 30- 86 30- 88 30- 89 30- 91 30- 95 30- 97 30- 99 30- 101 WA1200-6

Table of Contents

Testing and adjusting work equipment pump TVC valve oil pressure ................................. Operation test of work equipment valve by work equipment speed (speed of work equipment is low)................................................................................................................. Testing hydraulic oil cooler performance ............................................................................. Bleeding air from hydraulic circuit........................................................................................ Releasing remaining pressure in hydraulic circuit ............................................................... Work equipment...................................................................................................................... Checking center hinge pin lubrication.................................................................................. Adjustment method of auto grease injector delivery ............................................................ Setting method of auto grease timer.................................................................................... Electrical system ..................................................................................................................... Testing and adjusting bucket proximity switch..................................................................... Adjusting lift arm potentiometer ........................................................................................... Adjusting lift arm levelness detecting switch........................................................................ Initial setting procedure for remote boom positioner (origin input method).......................... Checking proximity switch operation pilot lamp ................................................................... Adjusting AJSS lever angle sensor and frame angle sensor ............................................... Testing and adjusting potentiometer mounting position ...................................................... Procedure for testing diodes................................................................................................ Basic precautions for KOMTRAX Plus controller................................................................. Inspection and maintenance of KOMTRAX Plus controller ................................................. Initial setting procedure for KOMTRAX Plus controller ........................................................ Precautions for replacing KOMTRAX Plus controller .......................................................... Measurement procedure by downloading data in KOMTRAX Plus controller ..................... Measurement procedure by multi monitor ........................................................................... Special functions of multi monitor ........................................................................................ Pm Clinic................................................................................................................................. Outline of measurement procedure for Pm Clinic ................................................................ Preparation for measurement for Pm Clinic......................................................................... Pm clinic service .................................................................................................................. 40 Troubleshooting General information on troubleshooting.................................................................................. Symptom and troubleshooting numbers .............................................................................. Sequence of events in troubleshooting................................................................................ Check before troubleshooting.............................................................................................. Classification and procedures of troubleshooting ................................................................ Breakage of hydraulic cylinder............................................................................................. Failure codes table .............................................................................................................. Symptom and troubleshooting numbers .............................................................................. Information in troubleshooting table..................................................................................... Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... Layout drawing of connector pins ........................................................................................ Connector list and layout ..................................................................................................... T- branch box and T- branch adapter table ......................................................................... Table of fuse locations......................................................................................................... Troubleshooting by failure code.............................................................................................. Failure code [1500L0] Double Engagement of Transmission Clutches ............................... Failure code [1540N1] T/M overrun ..................................................................................... Failure code [15B0NX] T/M Oil Filter Clogged..................................................................... Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit .................................................. Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect ......................................... Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit.................................................. Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect......................................... WA1200-6

30- 105 30- 107 30- 114 30- 117 30- 122 30- 123 30- 123 30- 125 30- 126 30- 128 30- 128 30- 129 30- 130 30- 131 30- 132 30- 133 30- 134 30- 137 30- 138 30- 147 30- 148 30- 165 30- 173 30- 177 30- 179 30- 236 30- 236 30- 237 30- 238

40- 8 40- 8 40- 9 40- 10 40- 21 40- 24 40- 27 40- 43 40- 44 40- 46 40- 48 40- 84 40- 104 40- 107 40- 110 40- 110 40- 111 40- 112 40- 114 40- 116 40- 118 40- 120 00-5

Table of Contents

Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit................................................... Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect.......................................... Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit................................................... Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect.......................................... Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit .................................................. Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect ......................................... Failure code [2F00MA] Parking brake circuit failure ............................................................ Failure code [2G42ZG] Accumulator Oil Press. F Low ........................................................ Failure code [2G43ZG] Accumulator Oil Press. R Low........................................................ Failure code [44K0L4] Bucket cylinder position detector SW failure ................................... Failure code [7REAKA] ACC Signal Malfunction ................................................................. Failure code [989P00] Direction protection warning ............................................................ Failure code [989Q00] Work equipment protection ............................................................. Failure code [989R00] Tire slip ............................................................................................ Failure code [989S00] Parking Brake Dragging................................................................... Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF).................................. Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) ................................... Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) ................................... Failure code [989W00] Stationary steering (Brake: ON, Load: ON) .................................... Failure code [AA1ANX] Air Cleaner 1 Clogging................................................................... Failure code [AA1BNX] Air Cleaner 2 Clogging................................................................... Failure code [AA1CNX] Air Cleaner 3 Clogging................................................................... Failure code [AA1DNX] Air Cleaner 4 Clogging................................................................... Failure code [AB00L6] Discharge of alternator R terminal................................................... Failure code [AB00MA] Discharge of alternator R terminal ................................................. Failure code [AB00MB] Discharge of alternator R terminal ................................................. Failure code [B@BCZK] Drop in Engine Coolant Level....................................................... Failure code [b@C5ZK] Low brake fluid level (before engine start) .................................... Failure code [B@C5ZK] Low brake fluid level (while engine is running) ............................. Failure code [B@C6NS] High brake oil temp....................................................................... Failure code [b@CENS] High torque converter oil temp. .................................................... Failure code [B@CENS] Very high torque converter oil temp. ............................................ Failure code [B@GAZK] Low battery 1 fluid level................................................................ Failure code [B@GBZK] Low battery 2 fluid level................................................................ Failure code [B@GCZK] Low battery 3 fluid level................................................................ Failure code [B@HANS] High hydraulic oil temp................................................................. Failure code [B@HAZK] Low hydraulic oil level................................................................... Failure code [D191KA] Neutral Output Relay Disconnection............................................... Failure code [D191KB] Neutral Output Relay hot short ....................................................... Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit) ............ Failure code [D19MKY] SW pump PNC solenoid Relay hot short....................................... Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure ...................................... Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure ...................................... Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)............. Failure code [D5ZHKB] Starting Switch C signal circuit Hot short ....................................... Failure code [D5ZHKZ] Starting Switch C signal circuit failure ............................................ Failure code [D5ZHL6] Ignition C terminal Circuit Failure.................................................... Failure code [DAF5KP] Monitor Panel 5 V source sys Error ............................................... Failure code [DAFRKR] Communication Lost Monitor Panel Controller.............................. Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source.................... Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal.................................... Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source ............. Failure code [DAQRKR] Communication Lost T/M Controller ............................................. Failure code [DAQRMA] Defective Option Selection Data in Transmission ........................ 00-6

40- 122 40- 124 40- 126 40- 128 40- 130 40- 132 40- 135 40- 138 40- 140 40- 142 40- 143 40- 144 40- 144 40- 145 40- 146 40- 148 40- 149 40- 150 40- 151 40- 152 40- 154 40- 156 40- 158 40- 160 40- 162 40- 164 40- 166 40- 168 40- 169 40- 170 40- 171 40- 172 40- 174 40- 176 40- 178 40- 180 40- 181 40- 182 40- 184 40- 186 40- 188 40- 190 40- 192 40- 194 40- 196 40- 198 40- 200 40- 202 40- 204 40- 206 40- 208 40- 210 40- 212 40- 214 WA1200-6

Table of Contents

Failure code [DB2RKR] Communication Lost Engine Controller......................................... Failure code [DB90KK] Drop in Work Controller Main Power Source ................................. Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal .................................... Failure code [DB92KK] Solenoid Voltage Failure (Work controller) .................................... Failure code [DB95KX] 5 V source sys Error (Work controller) ........................................... Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller ............ Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller ........ Failure code [DB9RMC] Communication Lost (Work Controller)......................................... Failure code [DBB0KK] VHMS source voltage Error ........................................................... Failure code [DBB0KQ] VHMS Connector Mismatch .......................................................... Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V) ........................ Failure code [DBB5KP] VHMS 5 V source sys Error ........................................................... Failure code [DBB6KP] VHMS 24 V source sys Error ......................................................... Failure code [DBB7KP] VHMS 12 V source sys Error ......................................................... Failure code [DBBQMC] Communication Lost (VHMS CAN0) ............................................ Failure code [DBBRKR] Communication Lost VHMS Controller ......................................... Failure code [DBBRMC] Communication Lost (VHMS CAN1) ............................................ Failure code [DD10KX] Verification Mode SW Failure ........................................................ Failure code [DD1ALD] Remote positioner upper side set sw failure .................................. Failure code [DD1BLD] Remote positioner lower side set sw failure .................................. Failure code [DDA7L4] Throttle Lock Input signal Short Circuit .......................................... Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit ....................... Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit....................... Failure code [DDB6L4] Neutral Signal Malfunction ............................................................. Failure code [DDD7KA] Speed control dial circuit (Low Voltage) ........................................ Failure code [DDD7KB] Speed control dial circuit (High Voltage) ....................................... Failure code [DDDBKA] Traction control dial circuit (Low Voltage) ..................................... Failure code [DDDBKB] Traction control dial circuit (High Voltage) .................................... Failure code [DDE5MA] Emergency steering signal Failure................................................ Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection........................................ Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit .......................................... Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)......... Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect .. Failure code [DDT4LD] T/M Cut Off set switch signal short circuit ...................................... Failure code [DDW9LD] Kickdown Switch Short Circuit ...................................................... Failure code [DGE5KX] Ambient air temp Sensor Failure................................................... Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect ............. Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check) .......... Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure........................................ Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection ................................ Failure code [DGR2KX] Brake oil temp. sensor circuit failure ............................................. Failure code [DGT1KX] T/C oil temp. sensor circuit failure ................................................. Failure code [DH20KX] Torque converter pressure sensor circuit ...................................... Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit).............. Failure code [DH21KB] Loader pump oil press sensor hot short......................................... Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit) ............................ Failure code [DHPCKX] Boom bottom press. sensor circuit failure..................................... Failure code [DHPCKY] Boom bottom press. hot short....................................................... Failure code [DHPDKX] Boom head press. sensor circuit failure ........................................ Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect ............................ Failure code [DHT2L6] T/M oil filter sensor circuit failure .................................................... Failure code [DHT3KX] Transmission main pressure sensor circuit ................................... Failure code [DHT4KX] Main PPC oil pressure sensor circuit ............................................. WA1200-6

40- 216 40- 218 40- 220 40- 222 40- 224 40- 226 40- 228 40- 230 40- 232 40- 234 40- 236 40- 238 40- 240 40- 242 40- 243 40- 245 40- 246 40- 248 40- 250 40- 252 40- 254 40- 256 40- 258 40- 260 40- 262 40- 264 40- 266 40- 268 40- 270 40- 272 40- 274 40- 276 40- 278 40- 280 40- 282 40- 284 40- 286 40- 288 40- 290 40- 292 40- 294 40- 296 40- 298 40- 300 40- 302 40- 304 40- 306 40- 308 40- 310 40- 312 40- 314 40- 316 40- 318 40- 320 00-7

Table of Contents

Failure code [DHT5KX] Torque converter intake pressure sensor circuit............................ Failure code [DHT8KX] Steering Oil Press. Sensor Failure................................................. Failure code [DHTAKX] Transmission lubrication pressure sensor circuit........................... Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect................... Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit .................. Failure code [DHU2KA] F Brake Oil press Sensor Disconnect............................................ Failure code [DHU2KB] F Brake Oil press Sensor Hot short............................................... Failure code [DHU2KX] F Brake Oil press Sensor Failure .................................................. Failure code [DHU3KA] R Brake Oil press Sensor Disconnect ........................................... Failure code [DHU3KB] R Brake Oil press Sensor Hot short .............................................. Failure code [DHU3KX] R Brake Oil press Sensor Failure .................................................. Failure code [DJF1KA] Fuel level sensor circuit Disconnection........................................... Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit).................. Failure code [DK30KY] Steering lever angle sensor circuit hot short .................................. Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit) ......... Failure code [DK59KY] Boom lever potentiometer (main) hot short .................................... Failure code [DK59L8] Boom lever potentiometer (main & sub) failure............................... Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)........... Failure code [DK5AKY] Boom lever potentiometer (sub) hot short...................................... Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit) ....... Failure code [DK5BKY] Bucket lever potentiometer (main) hot short .................................. Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure............................. Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)......... Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short.................................... Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit) .............................. Failure code [DKA0KX] Boom angle sensor circuit failure................................................... Failure code [DKA0KY] Boom angle sensor circuit hot short............................................... Failure code [DKA0L0] Boom angle sensor failure .............................................................. Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)............................. Failure code [DKD0KY] Frame angle sensor circuit hot short ............................................. Failure code [DKD0KZ] Frame and steering angle sensor failure ....................................... Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect ............................................ Failure code [DKH0KB] Angle sensor circuit (FR) Hot short................................................ Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect............................................. Failure code [DKH1KB] Angle sensor circuit (LR) Hot short................................................ Failure code [DLE2KA] Engine Speed Sensor Disconnection............................................. Failure code [DLE2LC] Engine Speed Sensor Short Circuit................................................ Failure code [DLF6LC] Tire speed sensor circuit................................................................. Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect ....................................... Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit ..................................... Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit ................................. Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection............................... Failure code [DT20KB] Transmission cut off indicator Output short circuit.......................... Failure code [DT21KB] Speed Control indicator Output short circuit................................... Failure code [DUM8KB] VHMS Operation lamp Short Circuit ............................................. Failure code [DV00KY] Buzzer circuit hotshort (for usually) ................................................ Failure code [DV01KY] Buzzer circuit hotshort (for special) ................................................ Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection......................... Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit............................ Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short ...................... Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection ........................ Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit ........................... Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short ...................... Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection ...................... 00-8

40- 322 40- 324 40- 326 40- 328 40- 330 40- 332 40- 334 40- 336 40- 338 40- 340 40- 341 40- 343 40- 344 40- 345 40- 346 40- 348 40- 349 40- 352 40- 354 40- 356 40- 358 40- 359 40- 362 40- 363 40- 364 40- 366 40- 368 40- 370 40- 372 40- 373 40- 374 40- 375 40- 376 40- 378 40- 380 40- 382 40- 384 40- 386 40- 388 40- 390 40- 392 40- 394 40- 396 40- 397 40- 398 40- 400 40- 402 40- 404 40- 405 40- 406 40- 407 40- 408 40- 409 40- 410 WA1200-6

Table of Contents

Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit ......................... Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short.................... Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection ................................. Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault .................................. Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short ....................................... Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection .............................. Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit ............................ Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short ................................ Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection................................... Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault...................................... Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short........................................... Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection ................................. Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit ................................. Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short...................................... Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection ................................. Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault .................................. Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short ....................................... Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection ........................ Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault ................................. Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short ...................................... Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection ...................................... Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault ........................................... Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short .............................................. Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection ................................. Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit..................................... Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short ......................................... Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection ............................ Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit............................... Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short ......................... Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection .................. Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit...................... Failure code [DWM1KY] Work equipment neutral lock solenoid hot short .......................... Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection.................... Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit ....................... Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short............................ Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection..................... Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit ........................ Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short............................. Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection ...................... Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit ........................... Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short................................ Failure code [DWNAKA] NC solenoid disconnection........................................................... Failure code [DWNAKB] NC solenoid short circuit .............................................................. Failure code [DWNAKY] NC solenoid hot short................................................................... Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit) ............... Failure code [DXA1KY] Loader pump solenoid Relay hot short .......................................... Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit) .............. Failure code [DXF0KA] AJSS EPC solenoid disconnection ................................................ Failure code [DXF0KB] AJSS EPC solenoid short circuit.................................................... Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection................................... Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit...................................... Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short ................................ Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection.................................. Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit .................................... WA1200-6

40- 411 40- 412 40- 413 40- 414 40- 415 40- 416 40- 417 40- 418 40- 419 40- 420 40- 421 40- 422 40- 423 40- 424 40- 425 40- 426 40- 427 40- 428 40- 429 40- 430 40- 431 40- 432 40- 433 40- 434 40- 435 40- 436 40- 437 40- 438 40- 439 40- 440 40- 441 40- 442 40- 443 40- 444 40- 445 40- 446 40- 447 40- 448 40- 449 40- 450 40- 451 40- 452 40- 453 40- 454 40- 455 40- 457 40- 459 40- 461 40- 463 40- 465 40- 467 40- 469 40- 471 40- 473 00-9

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Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short ............................... Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection................................... Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit ..................................... Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short ................................ Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection ..................................... Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit ........................................ Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short................................... Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection...................................... Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit ........................................ Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short ................................... Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection ........................... Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit .............................. Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V.................. Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction ............................... Troubleshooting of electrical system (E-mode),...................................................................... E-1 Remote positioner "RAISE" or "LOWER" LED does not light up................................... E-2 Open circuit or ground fault in check lamp system........................................................ E-3 Machine monitor does not operate................................................................................ E-4 Turn signal lamp does not light up ................................................................................ E-5 Defective parking lamp.................................................................................................. E-6 Defective front working lamp ......................................................................................... E-7 Defective rear working lamp.......................................................................................... E-8 Headlamp does not light up........................................................................................... E-9 Service meter does not work, or service meter works while engine is stopped. ........... E-10 Monitor panel controller does not sound buzzer ......................................................... E-11 Defective auto-greasing system .................................................................................. Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor) ....................................................................................................................... Work equipment hydraulic system, general ......................................................................... Work equipment oil pressure group ..................................................................................... Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)................................................................................................................................ Checking steering related standard values.......................................................................... Steering oil pressure system, general.................................................................................. Steering oil pressure group.................................................................................................. Brake oil pressure system, general...................................................................................... Brake oil pressure group...................................................................................................... Information contained in troubleshooting table (H mode) .................................................... H-1 Torque converter oil temperature rises too high (overheats) ........................................ H-2 Turning or response of steering is poor ........................................................................ H-3 AJSS lever is hard to operate ....................................................................................... H-4 Steering shakes or jolts................................................................................................. H-5 Wheel brake does not work at all or is weak................................................................. H-6 Lift arm speed is low or lift arm rising force is insufficient ............................................. H-7 Shock is large when lift arm stops................................................................................. H-8 Hydraulic oil temperature rises too high (overheating).................................................. 50 Disassembly and assembly General information on disassembly and assembly ............................................................... How to read Disassembly and Assembly............................................................................. Coating materials list............................................................................................................ Special tool list ..................................................................................................................... Sketches of special tools ..................................................................................................... 00-10

40- 475 40- 477 40- 479 40- 481 40- 483 40- 485 40- 487 40- 489 40- 491 40- 493 40- 494 40- 495 40- 496 40- 497 40- 499 40- 499 40- 500 40- 501 40- 502 40- 504 40- 506 40- 508 40- 510 40- 512 40- 514 40- 516 40- 518 40- 518 40- 528 40- 530 40- 595 40- 608 40- 609 40- 610 40- 650 40- 651 40- 701 40- 702 40- 705 40- 708 40- 710 40- 712 40- 714 40- 717 40- 718

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Table of Contents

Flushing procedure ................................................................................................................. Flushing procedure for brake circuit .................................................................................... Flushing procedure for work equipment and steering circuit ............................................... Air bleeding procedure............................................................................................................ Bleeding air from brake circuit ............................................................................................. Bleeding air from piston pump ............................................................................................. Bleeding air from work equipment circuit and steering circuit.............................................. Engine and cooling system ..................................................................................................... Removal and installation of radiator and hydraulic oil cooler assembly .............................. Removal and installation of engine assembly...................................................................... Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly .............................................................................. Removal and installation of water-cooled torque converter and transmission oil cooler assembly ............................................................................................... Removal and installation of damper assembly .................................................................... Disassembly and assembly of damper ................................................................................ Removal and installation of bumper and fuel tank assembly............................................... Removal and installation of hood assembly ........................................................................ Disassembly and assembly procedures for MESABI oil cooler ........................................... Disassembly and assembly of MESABI oil cooler ............................................................... Power train.............................................................................................................................. Removal and installation of torque converter and transmission assembly .......................... Disconnection and connection of transmission assembly and torque converter assembly . Disconnection and connection of torque converter assembly, PTO and transfer assembly Disassembly and assembly of torque converter .................................................................. Disassembly and assembly of modulation clutch ................................................................ Disassembly and assembly of PTO and transfer................................................................. Disconnection and connection of transmission assembly, transfer, and parking brake assembly .................................................................................................... Disassembly and assembly of transmission assembly ........................................................ Disassembly and assembly of transfer ................................................................................ Disassembly and assembly of parking brake ...................................................................... Removal and installation of parking brake assembly (installed on the machine) ................ Removal and installation of transmission, brake cooling device and brake pump assembly Removal and installation of steering pump, control pump and PPC pump assembly ......... Disassembly and assembly of drive shaft............................................................................ Removal and installation of front axle assembly.................................................................. Removal and installation of front final drive assembly ......................................................... Removal and installation of rear axle assembly .................................................................. Removal and installation of rear final drive assembly.......................................................... Removal and installation of differential assembly ................................................................ Disassembly and assembly of differential............................................................................ Disassembly and assembly of final drive and brake ............................................................ Removal and installation of center support assembly ......................................................... Disassembly and assembly of center support ..................................................................... Steering system ...................................................................................................................... Removal and installation of steering demand valve assembly ............................................ Removal and installation of steering cylinder assembly ...................................................... Removal and installation of emergency diverter valve assembly ........................................ Removal and installation of emergency steering pump assembly ....................................... Brake system .......................................................................................................................... Removal and installation of brake accumulator charge valve assembly ............................. Removal and installation of brake oil tank assembly ...........................................................

50505050505050505050-

54 54 60 66 66 68 69 72 72 79

50- 86 50- 88 50- 89 50- 91 50- 98 50- 100 50- 102 50- 105 50- 113 50- 113 50- 120 50- 127 50- 131 50- 142 50- 146 50- 159 50- 166 50- 187 50- 194 50- 197 50- 201 50- 202 50- 203 50- 205 50- 207 50- 209 50- 220 50- 223 50- 225 50- 238 50- 251 50- 253 50- 257 50- 257 50- 258 50- 262 50- 264 50- 265 50- 265 50- 266

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00-11

Table of Contents

Undercarriage and frame ........................................................................................................ Procedure for disconnecting front frame and rear frame ..................................................... Removal and installation of center hinge pin ....................................................................... Hydraulic system..................................................................................................................... Removal and installation of hydraulic tank, filter case assembly ......................................... Removal and installation of No. 1 work equipment pump assembly.................................... Removal and installation of No. 2 work equipment pump assembly.................................... Removal and installation of switch pump assembly............................................................. Removal and installation of work equipment control valve assembly .................................. Work equipment...................................................................................................................... Removal and installation of bucket cylinder assembly......................................................... Removal and installation of lift cylinder assembly................................................................ Disassembly and assembly of work equipment cylinder...................................................... Removal and installation of work equipment assembly ....................................................... Procedure for running in bucket pin ..................................................................................... Procedure for running in lift arm pin..................................................................................... Cab ......................................................................................................................................... Removal and installation of bulkhead assembly .................................................................. Removal and installation of operator's cab and floor assembly ........................................... Removal and installation of operator's cab assembly .......................................................... Removal and installation of air conditioner unit assembly ................................................... Disassembly and assembly of operator seat ....................................................................... Electrical system ..................................................................................................................... Removal and installation of DT connector pin ..................................................................... Removal and installation of HD connector pin ..................................................................... Repairing HD connector pin harness ................................................................................... Removal and installation of controller assembly.................................................................. 60 Maintenance standard Engine and cooling system ..................................................................................................... Engine mount....................................................................................................................... Cooling system .................................................................................................................... Cooling fan motor................................................................................................................. Damper ................................................................................................................................ Power train.............................................................................................................................. Transmission mount............................................................................................................. Torque converter.................................................................................................................. Main relief valve, torque converter relief valve..................................................................... Torque converter regulator valve ......................................................................................... ECMV................................................................................................................................... Transmission........................................................................................................................ Transmission control valve .................................................................................................. Lubrication relief valve ......................................................................................................... Transfer................................................................................................................................ Torque converter pump, transmission pump, brake cooling pump, brake pump ................. Drive shaft............................................................................................................................ Center support ..................................................................................................................... Differential............................................................................................................................ Final drive ............................................................................................................................ Steering system ...................................................................................................................... Steering pump...................................................................................................................... Switch pump ........................................................................................................................ Steering demand valve ........................................................................................................ Diverter valve ....................................................................................................................... 00-12

50- 267 50- 267 50- 268 50- 284 50- 284 50- 286 50- 288 50- 289 50- 290 50- 304 50- 304 50- 315 50- 329 50- 335 50- 391 50- 393 50- 396 50- 396 50- 398 50- 402 50- 404 50- 406 50- 439 50- 439 50- 441 50- 442 50- 443

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3 3 4 5 7 8 8 10 14 16 17 18 20 23 24 26 28 30 32 36 38 38 39 41 43

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Table of Contents

Steering cylinder mount ....................................................................................................... Steering cylinder .................................................................................................................. Emergency steering pump................................................................................................... Brake system .......................................................................................................................... Brake valve .......................................................................................................................... Slack adjuster ...................................................................................................................... Brake ................................................................................................................................... Parking brake....................................................................................................................... Undercarriage and frame ........................................................................................................ axle mount ........................................................................................................................... Center hinge pin .................................................................................................................. Hydraulic system .................................................................................................................... No.1 work equipment pump................................................................................................. No.2 work equipment pump................................................................................................. PPC relief valve ................................................................................................................... Pump control relief valve ..................................................................................................... Work equipment control valve ............................................................................................. Work equipment...................................................................................................................... Work equipment linkage ...................................................................................................... Bucket positioner, remote positioner ................................................................................... Work equipment cylinder ..................................................................................................... Electrical system ..................................................................................................................... Work equipment control lever .............................................................................................. 80 Appendix Air conditioner ......................................................................................................................... Precautions for refrigerant ................................................................................................... Configuration and function of refrigeration cycle ................................................................. Outline of refrigeration cycle ................................................................................................ Control system..................................................................................................................... Air conditioner components ................................................................................................. Compressor ......................................................................................................................... Electric fan and condenser .................................................................................................. Receiver drier ...................................................................................................................... Service tools ........................................................................................................................ Troubleshooting procedures ................................................................................................ Interview and confirmation of failure symptom .................................................................... Basic checks........................................................................................................................ Troubleshooting ................................................................................................................... Checking of refrigeration cycle ............................................................................................ Troubleshooting for unusual noise....................................................................................... Electrical system.................................................................................................................. Parts replacement................................................................................................................ Periodic inspection and maintenance .................................................................................. Testing and adjusting compressor belt tension ................................................................... 90 Diagrams and drawings Hydraulic circuit diagram ........................................................................................................ Circuit symbols used in hydraulic circuit diagrams .............................................................. Transmission hydraulic circuit diagram................................................................................ Brake hydraulic circuit diagram............................................................................................ Work equipment hydraulic circuit diagram........................................................................... Electrical circuit diagram ......................................................................................................... Circuit symbols used in electrical circuit diagrams .............................................................. 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44 45 47 48 48 50 51 52 54 54 56 59 59 62 65 66 67 69 69 74 75 77 77

8080808080808080808080808080808080808080-

3 3 4 5 7 11 18 19 21 22 29 30 31 32 38 46 47 49 52 56

90- 3 90- 3 90- 6 90- 8 90- 11 90- 15 90- 15 00-13

Table of Contents

Electrical circuit diagram ...................................................................................................... 90- 19 Index ....................................................................................................................................... 1

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Table of Contents

WA1200-6

00-15

Foreword and general information Safety notice

Foreword and general information

Safety notice
Important safety notice

0 -16
(Rev. 2010/03)

0 -16

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 Komatsu. 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 indicated 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 danger. Read and understand what is described in the Operation and Maintenance Manual before operating the machine. Read and understand what is described in this manual before starting work. 1)Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2)Locate a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3)When performing any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. qAlways wear the safety glasses when hitting parts with a hammer. qAlways wear the safety glasses when grinding parts with a grinder, etc. 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 operator's compartment. 5)Only qualified workers must perform the work and operation which require license or qualification. 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.

7)If welding repairs are needed, always have a trained and experienced welder perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8)Before starting work, warm up your body thoroughly to start work under good condition. 9)Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition and at the provided place.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals 5 Prohibition of operation and handling by unlicensed workers 6 Safety check before starting work 7 Wearing protective goggles (for cleaning or grinding work) 8 Wearing shielding goggles and protectors (for welding work) 9 Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much

00-16

WA1200-6

Foreword and general information 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 equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment 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. 4)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. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1)Before disconnecting or removing components for the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2)The coolant and oil in the circuits are hot when the engine is shut down, so be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or water circuits. 3)Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts. 4)Before starting work, remove the cables from the battery. Always remove the cable from the negative () terminal first. 5)When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. WA1200-6

6)When removing a cover which is under internal pressure or under pressure by a spring, always leave two bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7)When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8)When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires. 9)As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11)When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that connections of them are correct. 12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speeds, be particularly careful to check that they are installed correctly. 13)When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14)When measuring hydraulic pressure, check that the measuring tools are correctly installed. 15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

00-17

Foreword and general information Safety notice

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 operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. qDo not stand under the load. qDo not step on the load. 2)Check the slings before starting sling work. 3)Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4)Measure the weight of the load by the eye and check its center of gravity. 5)Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6)Do not sling a load with one wire rope alone. If it is slung so, It may rotate and may slip out of the rope. Install two or more wire ropes symmetrically. kSlinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7)Limit the hanging angle to 60 degree, as a rule. Do not sling a heavy load (25 kg or more) with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the two ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the two ropes make a hanging angle of 120 degree. If the two ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150 degree, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.

8)When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9)Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10)Apply wire ropes to the middle portion of the hook. qSlinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.

11)Do not use twisted or kinked wire ropes. 12)When lifting up a load, observe the following. qWind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. qAfter the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

00-18

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Foreword and general information Safety notice

the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. qDo not lift up the load at an angle. 13)When lowering a load, observe the following. qWhen lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. qCheck that the load is stable, and then remove the sling. qRemove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. 5. Precautions for using mobile crane aRead the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead traveling crane kA hoist crane or similar device must be used for lifting a heavy load (25 kg or more). The weight of a part that is 25 kg or more is indicated with the symbol "4" in "Disassembly and assembly". 1)Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, ground fault circuit interrupter, crane collision prevention device, and power application warning lamp, and check safety. 2)Observe the signals for sling work. 3)Operate the hoist at a safe place. 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 will not be an obstacle to work and passage. 11)After operating the hoist, do not swing the control switch. 12)Remember the position of the main switch so that you can turn off the power immediately in an emergency.

qIf

13)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition. 14)If you find an obstacle around the hoist, stop the operation. 15)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1)Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below
Wire ropes (Standard "Z" twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal diameter Allowable load of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4

aThe allowable load is one-sixth of the breaking strength of the rope to be used (Safety coefficient: 6).

WA1200-6

00-19

Foreword and general information Safety notice

8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit 1)Disconnection kAlthough the refrigerant (refrigerant gas: R134a) used on the machine's air conditioner is less destructive to the ozone layer for environmentally friendliness, it is not allowed to be released into the atmosphere as is. Whenever disconnecting the air conditioner gas circuit, be sure to recover the refrigerant 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 refrigerant 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)

aFor tightening torque, see the precautions for installation in each section of "Disassembly and assembly".

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Foreword and general information How to read the shop manual

How to read the shop manual

q q q

0 -21
(Rev. 2010/03)

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. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume 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 understanding for the structure of each component, but also serves as reference material for troubleshooting. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are explained in "Standard value table". 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 60. Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 80. Appendix This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections. 90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume) 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

Foreword and general information 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)...) 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
k

Item

Description Special safety precautions which are necessary when performing work are described. Special technical precautions or other precautions for preserving standards which are necessary when performing work are described. Weight of parts of component or parts are indicated. Caution necessary when selecting hoisting wire, or when working posture is important, etc. are described. Places that require special attention for tightening torque during assembly are indicated. Places to be coated with adhesives, etc. during assembly are indicated.

Safety

a
4 3 2 5 6

Caution

Weight

Tightening torque

Coat

Oil, coolant

Places where oil, etc. must be added, and capacity are indicated.

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 { }.

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Foreword and general information 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 machine maintenance work. The following terms are used to explain the criteria. 1. Standard dimension and tolerance qTo be accurate, the finished dimension of parts is slightly different from one to another. qTo specify the finished dimension of a part, a certain dimension is set for the part and an allowable difference from that dimension is indicated. qThe above dimension set is called the "standard dimension" and the range of difference from the standard dimension is called the "tolerance". qThe tolerance with the symbols of + or is indicated on the right side of the standard dimension.
Example: Standard dimension 120
qWhen

some parts are repaired, the value of performance/function is set to the standard value.

Tolerance -0.022 -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 dimension of the shaft to be inserted into that hole are indicated by the same standard dimension 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.
Example: Standard dimension 60 Tolerance Shaft Hole -0.030 +0.046 -0.076 0

2. Standard clearance and standard value qThe clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. qWhen some parts are repaired, the clearance is generally adjusted to the standard clearance. qThe values indicating performance and function of new products or equivalent are called the "standard value", which is indicated by a range or a target value.

3. Standard interference qWhen the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the "interference". qThe range (between A and B) from the difference (A) between the minimum dimension of the shaft and the maximum dimension of the hole to the difference (B) between the maximum dimension of the shaft and the minimum dimension of the hole is the standard interference. qAfter repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.

WA1200-6

00-23

Foreword and general information 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 "repair limit". qIf a part is worn to the repair limit, it must be replaced or repaired. qThe performance and function of a product lowers while it is used. A value with which the product can be used without causing a problem is called the "allowable value" or "allowable dimension". qIf a product deviates from the allowable value, it must be checked or repaired. However, since most of the allowable values are estimated from various tests or experiences in most cases, it must be judged after considering 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 interference". 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 replaced or repaired.

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Foreword and general information 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 performance 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.

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Foreword and general information 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 equipment, 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.

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Foreword and general information Method of disconnecting and connecting push-pull type coupler

Method of disconnecting and connecting push-pull type coupler

k k

0 -27

(Rev. 2010/03) Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to release the remaining pressure in the hydraulic tank. 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. 0 -2 7

Type 1

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 abnormality, however.

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Foreword and general information Method of disconnecting and connecting push-pull type coupler

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) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

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Foreword and general information Method of disconnecting and connecting push-pull type coupler

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 portion at the male end. (Fig. 10) 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) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

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Foreword and general information 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 before 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 improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment". Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wires connecting one component to another component, connectors 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 connectors) 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 disconnecting 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. 0 -30

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Foreword and general information Handling of electric equipment

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 connector, 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 compressed air completely before cleaning with compressed air.

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Foreword and general information Handling of electric equipment

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 installed.

qWhen

removing a connector from a clip, pull the connector in a parallel direction 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 improper contact to occur, so always cover the connector.

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Foreword and general information Handling of electric equipment

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 connector 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, replace 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 addition, 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.

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Foreword and general information Handling of electric equipment

3)Deutsch connector (DT 8-pin, 12-pin) Disconnection (Left of figure) While pressing locks (a) and (b), pull out the female connector (2). 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

Disconnection

Connection (Example of incomplete setting of (a))

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Foreword and general information Handling of electric equipment

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-pressure 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 contact, 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 connector 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.

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Foreword and general information Handling of electric equipment

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, FRAMATOME-2) q95/107/114/125/140/170/12V140 Series qVarious pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125/170/12V140 series) Oil pressure sensor: POIL (125/170/12V140 series) Oil pressure switch (95/107/114 series) Ne speed sensor on flywheel housing: NE (95/107/114/125/140/170/12V140 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". 2)Pull lock type (PACKARD-2) q95/107/114/125/140/170/12V140 Series qVarious temperature sensors Examples) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnection Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.

Connection Insert the connector straight until it "clicks".

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Foreword and general information Handling of electric equipment

3)Push lock type (1) q95/107/114 series Example) Fuel pressure common rail (BOSCH-03)

sensor

in

While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

Disconnection While pressing lock (C), pull out connector (3) in the direction of the arrow.
q

114 series

Connection Insert the connector straight until it "clicks". 4)Push lock type (2) q107/114 series Example) Intake air pressure/temperature sensor in intake manifold (SUMIq107

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 Insert the connector straight until it "clicks".

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Foreword and general information Handling of electric equipment

5)Push lock type (3) q95/125/140/170/12V140 series Disconnection While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)

Example) Intake air pressure sensor in intake manifold. (CANNON-04): PIM, etc.

Disconnection 1]Turn housing (H1) in the direction of the 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 harness 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 Insert the connector straight until it "clicks". 6)Turn-housing type (Round green connector) q140 series 00-38 WA1200-6

Foreword and general information Handling of electric equipment

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 disconnecting or connecting connectors. 2)Before performing troubleshooting, check all the related connectors for loose connection. aDisconnect and connect the related connectors several times to check. 3)Be sure to connect any disconnected connectors before going on to the next step. aIf the power is turned ON with the connectors still disconnected, unnecessary warning will be displayed. 4)When performing troubleshooting of circuits (measuring the voltage, resistance, continuity, 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 defective contact in the circuit.

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Foreword and general information 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 ple: 0.85 L --Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. 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 material of the cover.
(Table 1) Type Low-voltage wire for automobiles Thin low-voltage wire for automobile (type 1) Thin low-voltage wire for automobile (type 2) Heat resistant low-voltage wire for automobiles Symbol Conductor AV Insulator Conductor AVS Insulator Conductor CAVS Insulator Conductor AEX Insulator Material Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance Heat-resistant crosslinked polyethylene Temperature range for use ( C) Example of use

General wiring (nominal No. 5 and above)

-30 +60

General wiring (nominal No. 3 and below)

For mid- to small-size excavators (nominal No. 1.25 and below) General wiring in extremely cold weather district, wiring at high ambient temperature place

-50 +110

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Foreword and general information How to read electric wire code

2. Dimensions
(Table 2) Nominal No.
Number of strands/Diameter of strand Sectional area (mm2) d (approx.) AVS Standard Standard Standard

0.5f

(0.5)

0.75f

(0.85)

1.25f

(1.25)

2f

3f

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 0.51 1.0 2.0 2.0 0.56 0.76 1.2 2.2 2.2 0.88 1.27 1.5 2.5 2.7 1.29 1.96 1.9 2.9 3.0 2.09 1.9 2.9 3.1 3.08 2.3 3.5 3.30 2.4 3.6 3.8 5.23 3.0 4.6 4.6

Conductor

Cover D

AV AEX

Nominal No.
Number of strands/Diameter of strand Sectional area (mm2) d (approx.) AVS Standard Standard Standard

8 50/0.45 7.95 3.7 5.5 5.3

15 84/0.45 13.36 4.8 7.0 7.0

20 41/0.80 20.61 6.0 8.2 8.2

30 70/0.80 35.19 8.0 10.8 10.8

40

50

60

85

100

85/0.80 108/0.80 127/0.80 169/0.80 217/0.80 42.73 8.6 11.4 11.4 54.29 9.8 13.0 13.0 63.84 10.4 13.6 13.6 84.96 12.0 16.0 16.0 109.1 13.6 17.6 17.6

Conductor

Cover D

AV AEX

Nominal No.
Number of strands/Diameter of strand Sectional area (mm2) d (approx.)

0.5f

0.5 7/Circular compressed 0.56 0.9 1.6

0.75f

0.85 11/Circular compressed 0.88 1.1 1.8

1.25f

1.25 16/Circular compressed 1.29 1.4 2.1

Conductor

Cover D

CAVS

Standard

"f" of nominal No. denotes "flexible".

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Foreword and general information How to read electric wire code

3. Color codes table

(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow & Green Yellow & Blue Yellow & Red 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 Charge Ground Start Light Instrument Signal Type of circuit R B R RW Y G L Br Lg O Others Gr P Sb Dg Ch WG RB YR GW LW BrW LgR AVS, AV, CAVS RY YB GR LR BrR LgY RG YG GY LY BrY LgB RL YL GB LB BrB LgW YW GL R B R D Y G L AEX Gr Br

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Foreword and general information 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 given 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 disconnecting the connectors. Do not pull the wires. qAttach the tags to wires and hoses to show their installation position to prevent any mistake when installing. 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 alternately. qBefore removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering 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 number 02 03 04 05 06 10 12 Plug (nut end) 07376 - 70210 07376 - 70315 07376 - 70422 07376 - 70522 07376 - 70628 07376 - 71034 07376 - 71234 Sleeve nut (elbow end) 02789 - 20210 02789 - 20315 02789 - 20422 02789 - 20522 02789 - 20628 07221 - 21034 07221 - 21234

2)Split flange type hoses and tubes

Nominal number 04 05 Flange (hose end) 07379 - 00400 07379 - 00500 Sleeve head (tube end) 07378 - 10400 07378 - 10500 Split flange 07371 - 30400 07371 - 30500

3)If the part is not under hydraulic pressure, the following corks can be used.
Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part No. 07049 - 00608 07049 - 00811 07049 - 01012 07049 - 01215 07049 - 01418 07049 - 01620 07049 - 01822 07049 - 02025 07049 - 02228 07049 - 02430 07049 - 02734 D 6 8 10 12 14 16 18 20 22 24 27 Dimensions d 5 6.5 8.5 10 11.5 13.5 15 17 18.5 20 22.5 L 8 11 12 15 18 20 22 25 28 30 34

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Foreword and general information Precautions when performing work

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 leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.

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Foreword and general information Precautions when performing work

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".

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Foreword and general information 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 eter of bolt flats mm mm 6 10(10) 8 13(12) 10 17(14) 12 19(17) 14 22 16 24 18 27 20 30 22 32 24 36 27 41 30 46 33 50 36 55 39 60 Tightening torque Nm 11.8 14.7 27 34 59 74 98 123 157 196 245 309 343 427 490 608 662 829 824 1,030 1,180 1,470 1,520 1,910 1,960 2,450 2,450 3,040 2,890 3,630 kgm 1.2 1.5 2.8 3.5 6.0 7.5 10.0 12.5 16 20 25 31.5 35 43.5 50 62 67.5 84.5 84 105 120 150 155 195 200 250 250 310 295 370

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.
Thread diam- Width across eter of bolt flats mm mm 6 10 8 12 10 14 12 17 Tightening torque Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2 kgm 0.6 1.0 1.4 2.4 3.5 4.7 7.6 9.2

Fig. A

Fig. B

aValues with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.

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Foreword and general information Standard tightening torque table

2. Table of tightening torque for split flanged bolts aUnless otherwise specified, tighten split flanged bolts to the torque shown in the following table.
Thread diam- Width across eter of bolt flats mm mm 10 14 12 17 16 22 Tightening torque Nm 59 74 98 123 235 285 kgm 6.0 7.5 10.0 12.5 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.
Nominal No. 02 03, 04 05, 06 10, 12 14 Thread diam- Width across eter flats mm mm 14 Varies 20 depending on 24 type of con33 nector. 42 Tightening torque (Nm {kgm}) Range 35 63 {3.5 6.5} 84 132 {8.5 13.5} 128 186 {13.0 19.0} 363 480 {37.0 49.0} 746 1,010 {76.0 103} Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 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.
Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52 Thread diam- Width across eter flats mm mm 8 14 10 17 12 19 14 22 16 24 18 27 20 30 24 32 30 32 33 36 36 42 52 Tightening torque (Nm {kgm}) Range 5.88 8.82 {0.6 0.9} 9.8 12.74 {1.0 1.3} 14.7 19.6 {1.5 2.0} 19.6 24.5 {2.0 2.5} 24.5 34.3 {2.5 3.5} 34.3 44.1 {3.5 4.5} 44.1 53.9 {4.5 5.5} 58.8 78.4 {6.0 8.0} 93.1 122.5 { 9.5 12.5} 107.8 147.0 {11.0 15.0} 127.4 176.4 {13.0 18.0} 181.3 240.1 {18.5 24.5} 274.4 367.5 {28.0 37.5} Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 127.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

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Foreword and general information Standard tightening torque table

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}) Nominal Width number of across hose flats (mm) 02 03 04 05 06 (10) (12) (14) 19 22 24 27 32 36 41 46 55 Range 34 54 {3.5 5.5} 34 63 {3.5 6.5} 54 93 {5.5 9.5} 59 98 {6.0 10.0} 84 132 {8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0} Target 44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} Taper seal Thread size (mm) 14 18 22 24 30 33 36 42 Face seal Nominal No. Thread diameNumber of ter (mm) (Refthreads, type of erence) thread 9/16-18UN 14.3 11/16 16UN 17.5 13/16 16UN 20.6 1 14UNS 25.4 1-3/16 12UN 30.2

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 (wetted).
Tightening torque (Nm {kgm}) Outer diam- Width across eter of pipe flats (mm) (mm) 8 10 12 15 (16) 22 (20) 19 22 24 (27) 30 (32) 36 Range 14 16 {1.4 1.6} 24 27 {2.4 2.7} 43 47 {4.4 4.8} 60 68 {6.1 6.8} 90 95 {9.2 9.7} Target 15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4} Face seal Nominal No. Thread diameter Number of (mm) threads, type of (Reference) thread 9/16 18UN 14.3 11/16 16UN 17.5 13/16 16UN 20.6 1-14UNS 25.4 1 3/16 12UN 30.2

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

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Foreword and general information Standard tightening torque table

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 series to the torque shown in the following table.
Thread size mm 6 8 10 12 14 Nm 10 2 24 4 43 6 77 12 Tightening torque Bolts and nuts kgm 1.02 0.20 2.45 0.41 4.38 0.61 7.85 1.22

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 mm 6 8 10 12 14 Tightening torque Nm 82 10 2 12 2 24 4 36 5 kgm 0.81 0.20 1.02 0.20 1.22 0.20 2.45 0.41 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.
Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4 Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 2 1.53 0.20 51 0.51 0.10 20 2 2.04 0.20 15 2 1.53 0.20 25 3 2.55 0.31 20 2 2.04 0.20 35 4 3.57 0.41 25 3 2.55 0.31 55 6 5.61 0.61 35 4 3.57 0.41 75 8 7.65 0.82 45 5 4.59 0.51

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Foreword and general information List of abbreviation

List of abbreviation
q

0 -50

(Rev. 2010/03) This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, 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
Abbreviation A.B.S. A.I.S.S. A.J.S.S. Full Spelling Purpose of use (major applicable machine (*), or component/system) Travel and brake (HD, HM) Engine Explanation With this function, when the tires skid (wheels stop rotating), the brakes are released, and when the wheels start to rotate, the brakes are applied again. This function automatically sets the idle speed. Instead of a steering wheel, a lever is used to perform the steering operations as well as to shift gear and change direction (forward or reverse). When the machine is traveling downhill, if the accelerator pedal is released, this function automatically applies the retarder with a constant braking force. When the machine is traveling downhill, if the accelerator pedal is released, this function automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator. When the rear wheels spin on soft ground surfaces, this function automatically uses the optimum braking force to drive both wheels. A device that can be fixed onto a machine in order to enable it to do different jobs. When the retarder is not being used, this valve bypasses part of the brake cooling oil to reduce the load on the hydraulic pump. Communications standard standardized as ISO11898. System that can simultaneously actuate multiple actuators regardless of the load (provides better ease of combined operation than O.L.S.S.). Uses engine controller to perform electronic control of supply pump, common rail, and injector. Functions to maintain optimum fuel injection amount and fuel injection timing. Electronic control device that uses the signals from the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECU) Proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock. System that ensures smooth high-speed travel by using hydraulic spring effect of accumulator to absorb vibration of machine during travel Electronic control device that uses the signals from the sensors on the machine to indicate to the actuators the optimum actuation. (same as ECM) Functions to recirculate part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of Nox.

Anti-skid Brake System Automatic Idling Setting System

Advanced Joystick Steer- Steering ing System (WA) Automatic Retarder Accelerator Control Travel and brake (HD, HM)

A.R.A.C.

A.R.S.C.

Automatic Retarder Speed Control

Travel and brake (HD, HM) Travel and brake (HD, HM) Work equipment

A.S.R. ATT. B.C.V. C.A.N. C.L.S.S.

Automatic Spin Regulator Attachment

Brake Cooling oil control Brake Valve (HD) Controller Area Network Closed-center Load Sensing System Common Rail Injection Electronic Control Module Communication and electronic control Hydraulic

C.R.I.

Engine

E.C.M. E.C.M.V. E.C.S.S. E.C.U. E.G.R.

Electronic control system

Electric Control Modula- Transmission tion Valve (D, HD, WA, etc.) Electronically Controlled Travel Suspension System (WA) Electronic Control Unit Exhaust Gas Recirculation Electronic control system Engine

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Foreword and general information List of abbreviation

Abbreviation

Full Spelling

Purpose of use (major applicable machine (*), or component/system)

Explanation System that allows data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor on the machine to be checked on monitor. Control system that moves an actuator in proportion to the amperage of an electric current passing through the solenoid. Position of the gear shift lever or switch. System that is used to determine the current location on the Earth of a ship, car, machine, etc. by receiving the radio wave signals transmitted from the navigation satellites. Steering function that uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks to turn machine without using steering clutch. Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Same as IMV. Valve installed at inlet port of pump to adjust fuel 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 pixels filled with liquid crystal. Semiconductor element that emits light when the voltage is applied in forward direction, positive voltage to anode and negative voltage to cathode. Function that senses differential pressure of pump and controls discharge amount according to load. Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones. Device actuated to open electric or hydraulic circuits that are normally closed if not actuated. Device actuated to close electric or hydraulic circuits that are normally open if not actuated. Hydraulic system that can operate multiple actuators at the same time, regardless of the load. Controlling the oil pressure. System in which a controller instantly analyses data from each lever, pedal, and dial, and performs optimum electronic control of the engine and transmission. Valve installed at inlet port of pump to adjust fuel intake amount in order to control fuel discharge amount of supply pump. Control system that moves an actuator in proportion to the oil pressure. Piston pump and motor. A device to take off power of the engine. Function that performs hydraulic control of the tilt and pitch of the bulldozer blade.

Equipment Management E.M.M.S. Machine monitor Monitoring System E.P.C. F-N-R G.P.S. Electromagnetic ProporHydraulic tional Control Forward-Neutral-Reverse Operation Global Positioning System Communication (KOMTRAX, VHMS)

H.S.S.

Hydrostatic Steering Sys- Steering tem (D) Hydro Static Transmission Inlet Metering Actuator Inlet Metering Valve Liquid Crystal Display Light Emitting Diode Load Sensing Multimedia Messaging Service Normally Closed Normally Open Transmission (D, WA) Engine Engine Machine monitor Electronic parts Hydraulic Communication Electric and hydraulic Electric and hydraulic

H.S.T. I.M.A. I.M.V. L.C.D. L.E.D. L.S. M.M.S. N.C. N.O. O.L.S.S. P.C.

Open-center Load SensHydraulic ing System Pressure Control Hydraulic

Palm Command Control Steering P.C.C.S. System (D) P.C.V. P.P.C. P.P.M. P.T.O. P.T.P. Pump Control Valve Proportional Pressure Control Piston Pump and Motor Power Take Off Power Tilt and power Pitch dozer Engine Hydraulic Hydraulic (D, PC, etc.) Power transmission Work equipment (D)

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Foreword and general information List of abbreviation

Abbreviation

Full Spelling

Purpose of use (major applicable machine (*), or component/system)

Explanation International System of Units (abbreviated SI from the French Le Systeme Internationale dUnites) is the modern form of the metric system, and is the worlds most widely used system of measurement. Therere 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 magnetic force when the solenoid is energized. The word solenoid also often refers to a solenoid valve. Solenoid valve that switches over direction of flow.

S.I.

Le Systeme International Unit d Unites

SOL.

Solenoid

Electric

T.W.V.

Two Way Valve

Hydraulic and electric

Communications system that transmits machine data, such as the present position of the machine, Monitoring and communica- daily or aggregate hours of operation, fuel conVehicle 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 (Developed 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

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Foreword and general information List of abbreviation

List of abbreviations used in the circuit diagrams

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

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Foreword and general information Conversion table

Conversion table

0 -54

(Rev. 2010/03) 0 -54 Method of using the conversion table The conversion table in this section is provided to enable simple conversion of figures. For details of the method 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 millimeters 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 0 10 20 30 40 (A) 50 60 70 80 90 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.847 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740 (B) 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898

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Foreword and general information Conversion table

Millimeters to inches 0 10 20 30 40 50 60 70 80 90 0 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622 3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.847 3.268 3.661 4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701 5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929 2.283 2.677 3.071 3.465 3.858 2.323 2.717 3.110 3.504 3.898

Kilogram to pound 0 10 20 30 40 50 60 70 80 90 0 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42 1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62 2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83 3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03 4 8.82 30.86 52.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24 5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44 6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64 7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85 1 kg = 2.2046 lb 8 9 17.64 19.84 39.68 41.89 61.73 63.93 83.78 85.98 105.82 108.03 127.87 149.91 171.96 194.01 216.05 130.07 152.12 174.17 196.21 218.26

Liters to U.S. Gallons 0 10 20 30 40 50 60 70 80 90 0 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775 1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040 2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096 6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361 7 1.849 4.491 7.133 9.774 12.416 15.058 17.700 20.341 22.983 25.625

1 l = 0.2642 U.S.Gal 8 9 2.113 2.378 4.755 5.019 7.397 7.661 10.039 10.303 12.680 12.944 15.322 17.964 20.605 23.247 25.889 15.586 18.228 20.870 23.511 26.153

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Foreword and general information Conversion table

Liters to U.K. Gallons 0 10 20 30 40 50 60 70 80 90 kgm to ft.lb 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 0 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3 1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5 2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7 3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0 4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2 5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4 6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7 7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9 0 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.699 9.899 12.098 14.298 16.498 18.697 20.897 6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117 7 1.540 3.740 5.939 8.139 10.339 12.528 14.738 16.938 19.137 21.337

1 l = 0.21997 U.K.Gal 8 9 1.760 1.980 3.950 4.179 6.159 6.379 8.359 8.579 10.559 10.778 12.758 14.958 17.158 19.357 21.557 12.978 15.178 17.378 19.577 21.777

1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8 781.2 853.5 925.8 998.2 1070.5 1142.8 1215.1 1287.5 1359.8 1432.1 426.8 499.1 571.4 643.7 716.1 788.4 860.7 933.1 1005.4 1077.7 1150.0 1222.4 1294.7 1367.0 1439.4

00-56

WA1200-6

Foreword and general information Conversion table

kg/cm2 to lb/in2 0 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1,138 1,280 1,422 1,565 1,707 1,849 1,991 2,134 2,276 2,418 2,560 2,702 2,845 2,987 3,129 3,271 3,414 1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1,010 1,152 1,294 1,437 1,579 1,721 1,863 2,005 2,148 2,290 2,432 2,574 2,717 2,859 3,001 3,143 3,286 3,428 2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1,024 1,166 1,309 1,451 1,593 1,735 1,877 2,020 2,162 2,304 2,446 2,589 2,731 2,873 3,015 3,158 3,300 3,442 3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1,038 1,181 1,323 1,465 1,607 1,749 1,892 2,034 2,176 2,318 2,460 2,603 2,745 2,887 3,030 3,172 3,314 3,456 4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1,053 1,195 1,337 1,479 1,621 1,764 1,906 2,048 2,190 2,333 2,475 2,617 2,759 2,901 3,044 3,186 3,328 3,470 5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1,067 1,209 1,351 1,493 1,636 1,778 1,920 2,062 2,205 2,347 2,489 2,631 2,773 2,916 3,058 3,200 3,343 3,485 6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1,081 1,223 1,365 1,508 1,650 1,792 1,934 2,077 2,219 2,361 2,503 2,646 2,788 2,930 3,072 3,214 3,357 3,499 1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9 810.7 953.0 1,095 1,237 1,380 1,522 1,664 1,806 1,949 2,091 2,233 2,375 2,518 2,660 2,802 2,944 3,086 3,229 3,371 3,513 825.0 967.2 1,109 1,252 1,394 1,536 1,678 1,821 1,963 2,105 2,247 2,389 2,532 2,674 2,816 2,958 3,101 3,243 3,385 3,527 839.2 981.4 1,124 1,266 1,408 1,550 1,693 1,835 1,977 2,119 2,262 2,404 2,546 2,688 2,830 2,973 3,115 3,257 3,399 3,542

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240

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Foreword and general information Conversion table

Temperature

0 -5 8

Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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.
C -40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 F -40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 C -11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0 C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 1 C = 33.8F F 81 177.8 82 179.6 83 181.4 84 183.2 85 185.0 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0

-40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

00-58

WA1200-6

SEN0547504-00

01-

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

0-1

Machine model
WA1200-6

Serial number
60001 and up

01 Specification

01-

WA1200-6

01-1

Contents

Contents
01 Specification Specification............................................................................................................................ Specification dimension drawing.......................................................................................... Specifications....................................................................................................................... Weight table ......................................................................................................................... Table of fuel, coolant and lubricants .................................................................................... 01010101013 3 4 7 9

01-2

01-2

WA1200-6

Specification Specification dimension drawing

Specification

Specification dimension drawing

01-3
Dimensions in ( ) are for the machine equipped with 65/65-57-62PR tires. Dimensions marked with* and ** are for machines equipped with a rock bucket and limestone bucket respectively.

01-3

WA1200-6

01-3

Specification Specifications

Specifications
Machine model Serial number Weight Operating weight Load on front axle Load on rear axle Bucket capacity (heaped) Operating load Travel speed forward 1st Travel speed forward 2nd Performance Travel speed forward 3rd Travel speed reverse 1st Travel speed reverse 2nd Travel speed reverse 3rd Maximum rim pull Gradeability Center of outside tire Min. turning radius Outside of chassis (bucket with teeth) kg kg kg m3 kg km/h km/h km/h km/h km/h km/h kN {kg} degree mm mm mm mm mm mm mm mm mm mm mm mm mm degree degree mm WA1200-6 60001 and up 216,400 [221,440] 128,900 [131,900] 87,500 [89,540] 20.0 36,000 6.1 [6.0] 11.1 [10.9] 18.7 [18.3] 6.3 [6.2] 11.4 [11.2] 19.3 [18.9] 992 {101,200} [1,015 {103,480}] 25 12,015 14,330 18,310 [18,345] 5,820 [5,970] 6,400 (including cutting edges), 6,550 (including tire guards) 6,970 [6,930] 12,205 [12,165] 7,100 4,300 760 [715] 8,850 [8,810] 6,755 [6,725] 2,585 [2,690] 50.5 (with bucket fully raised) 50 590 [630]

01-4

Overall length (bucket with teeth) Overall width (chassis) Bucket width Overall height (to top of ROPS) Overall height (with bucket fully raised) Dimension Wheelbase Tread Min. ground clearance Maximum bucket hinge pin height Dumping clearance (cutting edge end) Dumping reach (cutting edge end) Bucket tilt-forward angle Bucket tilt-back angle Digging depth measured at cutting edge (with bucket 10 degree forward-tilt)

Dimensions in [ ] are for the machine equipped with 65/65-57-62PR tires.

01-4

WA1200-6

Specification Specifications

Machine model Serial number Foot brake Brake Hand brake Type Structure Quadruple type pump
q q q

WA1200-6 60001 and up Wet, multiple disc type brakes acting on front and rear wheels independently, hydraulically actuated Wet, multiple disc type brake acting on drive shaft (transmission output shaft), hydraulically released and spring applied Frame articulate steering Full hydraulic power steering

Steering system

Torque converter and transmission pump Brake cooling pump Brake pump

l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min l/min

752 (Gear pump: SAR (4) 200 + 200) 135 (gear pump: SAR (3) 71) 74.4 (gear pump: SAR (2) 40) 633 (variable displacement piston pump: HPV160 + 160) 385 (variable displacement piston pump HPV95 + 95) 74.4 (gear pump: SAL (2) 40) 633 (variable displacement piston pump: HPV160 + 160) 418 (gear pump: SAR (3) 125 + 100) 633 (variable displacement piston pump: HPV160 + 160) 135 (gear pump: SAR (2) 71) 126 (gear pump: SAR (2) 63) 352 (gear pump: SAM (3) 100 + 100) Fixed displacement piston motor: LMF40

Work equipment pump (1) Hydraulic pump delivery Work equipment pump (2)
q

Cooling fan pump

Switching pump
q

Hydraulic cooling pump

Steering pump Hydraulic system

q q

Hydraulic control pump PPC pump

Emergency steering pump Hydraulic motor Cooling fan motor Transmission valve Control Steering valve valve set pressure EPC valve Work equipment valve Steering cylinder number of cylinders - bore x stroke Lift arm cylinder number of cylinders - bore x stroke Bucket cylinder number of cylinders - bore x stroke

MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} MPa {kg/cm2} mm mm mm

2.65 {27} (spool type, electrically controlled) 31.4 {320} (spool type) 3.9 {40} (electromagnetic type) 31.4 {320} (2-spool type) Double-acting piston type 2 - 225 x 660 Double-acting piston type 2 - 360 x 1,835 Double-acting piston type 2 - 300 x 985 Z bar with duplex linkage

Cylinder

Work equipment

Type of link

Shape of bucket cutting edge

Spade nose with tip teeth

WA1200-6

01-5

Specification Specifications

Machine model Serial number Description Type Number of cylinders - bore x stroke Piston displacement (total piston displacement) Flywheel horsepower Engine Maximum torque Fuel consumption ratio Max. speed with no load Min. speed with no load Starting motor Alternator Battery Torque converter Power train Transmission Reduction gear unit Differential Final reduction gear Drive method Front axle Rear axle Axle and wheel Tire (standard) Tire (optional) Tire (optional) Wheel rim (60/80 tire) (standard) Wheel rim (65/65 tire) (optional) Inflation pressure (front wheel) Inflation pressure (rear wheel) kPa {kg/cm2} kPa {kg/cm2} mm l {cc} kW/rpm {PS/rpm} Nm/rpm {kgm/rpm} g/kWh {g/PSh} rpm rpm

WA1200-6 60001 and up SSDA16V160E-2 4-cycle, water-cooled, V-type 16-cylinder, direct injection, with turbocharger and aftercooler 16 - 159 x 190 60 {60,360} 1,310/1,800 {1,780/1,800} 8,150/1,500 {831/1,500} 208 {153} (at rated horsepower: gross) 1,900 650 24 V, 9.0 kW x 2 24 V, 140 A 12 V, 160 Ah x 6 3-element, 1-stage, 1-phase (TCA51-3) Planetary gear type, 3-forward and 3-reverse speeds Spiral bevel gear type Straight bevel gear type Planetary gear, double reduction, oil bath lubrication Front and rear wheel drive Full floating type, fixed to frame Full floating type, supported by center pin 60/80-R57 (L5) 65/65-57-62PR (L5) 58/85-57-84PR (L5) 47.00 x 57/5.0 52.00 x 57/6.0 690 {7.0} 590 {6.0}

01-6

WA1200-6

Specification Weight table

Weight table
Unit: kg Machine model Serial number Engine Radiator (including hydraulic oil cooler) Cooling fan motor Torque converter oil cooler Torque converter Transmission Damper Upper drive shaft Center drive shaft Front drive shaft Rear drive shaft Center support Front axle Rear axle Front differential Rear differential Planetary carrier (per carrier) Wheel hub (per hub) Axle pivot (rear axle) (front/rear) Tire (60 tire) (standard) (per tire) Tire (65 tire/58 tire) (optional) (per tire) Wheel (60 tire) (standard) (per wheel) Wheel (65 tire/58 tire) (optional) (per wheel) Steering valve Steering cylinder (per cylinder) Hydraulic tank (tank alone) Work equipment pump (pump 1/ pump 2) Torque converter pump + transmission pump + brake cooling pump + brake pump Switching pump + hydraulic cooling pump Steering pump + control pump + PPC pump Work equipment control valve (per valve) Lift arm cylinder (each) Bucket cylinder Fender (one side) Radiator guard Front frame Rear frame WA1200-6 60001 and up 8,570 2,776 13.9 209 1,456 3,781 375 112 186 275 287 164 16,248 16,590 1,618 1,843 880 710 625/960 5,894 7,100/6,033 1,895 2,050/1,963 66 584 1,459 (1,248) 193/180 72.8 237 221 95 2,963 1,399 135 850 15,750 18,480

01-7

WA1200-6

01-7

Specification Weight table

Unit: kg Machine model Serial number Bucket linkage (including bushing) (per linkage) Bell crank (including bushing) (per bell crank) Lift arm (including bushing) Bucket (with teeth) Rear bumper (including fuel tank) Fuel tank (side tank x 2, center tank x 1) Battery (per battery) Cab assembly Air conditioner unit Operator's seat Floor board ROPS support assembly WA1200-6 60001 and up 699 2,454 18,240 22,785 6,820 Side tank: 485 x 2, center tank: 622 64 588 11 50 235 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 Capacity Specified capacity Refill capacity Liters US gal Liters US gal Reservoir Capacity Specified capacity Refill capacity Liters US gal Liters US gal

Engine oil pan 300 79.26 280 73.98 Axle (both of front and rear axles) 670 177.01 670 177.01

Transmission case 370 97.75 300 79.26 Auto greasing system

Hydraulic oil system 2000 528.40 1360 359.31 Work equipment pin

Brake oil tank Brake Cooling 90 300 23.78 79.26 75 290 19.82 76.62 Cooling system 580 153.24 570 150.59 Fuel tank 5100 1347.42

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 enable 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 lubricating 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 respectively. Note 2: When using the machine equipped with the auto-greasing unit at temperatures below -20 C, use Lithium 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 Amount of Liters 165 SUPERCOOLANT US gal 43.59 (AF-NAC) Liters 385 Amount of water US gal 101.71 Amount of additive Liters US gal (DCA4) Volume ratio % 30 -15 198 52.31 352 92.99 36 -20 226 59.57 325 85.72 20 5.28 41 -25 253 66.84 297 78.46 46 -30 275 72.65 275 72.65 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 WA1200-6

Shop Manual

1-01

Machine model
WA1200-6

Serial number
60001 and up

10 Structure and function

10-1

WA1200-6

10-1

Contents

Contents
10 Structure and function Engine and cooling system ..................................................................................................... Damper ................................................................................................................................ Cooling system .................................................................................................................... Cooling fan motor................................................................................................................. Power train.............................................................................................................................. Power train........................................................................................................................... Hydraulic piping drawing of torque converter and transmission .......................................... Torque converter.................................................................................................................. Main relief valve and torque converter relief valve............................................................... Torque converter regulator valve ......................................................................................... ECMV................................................................................................................................... Transmission........................................................................................................................ Transmission control valve .................................................................................................. Transmission lubricating oil relief valve ............................................................................... Transfer................................................................................................................................ Torque converter oil cooler .................................................................................................. Center support ..................................................................................................................... Axle ...................................................................................................................................... Final drive ............................................................................................................................ Steering system ...................................................................................................................... Steering equipment layout drawing...................................................................................... AJSS .................................................................................................................................... Steering pump...................................................................................................................... Switch pump ........................................................................................................................ Steering demand valve ........................................................................................................ Rotary valve ......................................................................................................................... EPC valve (for steering)....................................................................................................... Diverter valve ....................................................................................................................... Emergency steering relief valve........................................................................................... Steering lock valve............................................................................................................... Brake system .......................................................................................................................... Brake equipment layout drawing.......................................................................................... Brake valve .......................................................................................................................... Charge valve........................................................................................................................ Accumulator (for brake) ....................................................................................................... Slack adjuster ...................................................................................................................... Brake.................................................................................................................................... Parking brake....................................................................................................................... Parking brake solenoid valve ............................................................................................... Emergency parking brake release valve.............................................................................. Check valve of parking brake circuit .................................................................................... Undercarriage and frame ........................................................................................................ Axle mount ........................................................................................................................... Center hinge pin................................................................................................................... Jack-up point........................................................................................................................ Hydraulic system..................................................................................................................... Hydraulic piping layout drawing ........................................................................................... Work equipment control lever linkage.................................................................................. Hydraulic tank ...................................................................................................................... Work equipment pump No.1 ................................................................................................ 10- 4 10- 4 10- 5 10- 6 10- 11 10- 11 10- 13 10- 15 10- 24 10- 27 10- 29 10- 35 10- 46 10- 56 10- 57 10- 59 10- 60 10- 61 10- 66 10- 67 10- 67 10- 68 10- 70 10- 72 10- 89 10- 99 10- 102 10- 103 10- 106 10- 107 10- 108 10- 108 10- 109 10- 115 10- 119 10- 120 10- 122 10- 123 10- 124 10- 125 10- 126 10- 129 10- 129 10- 131 10- 132 10- 133 10- 133 10- 135 10- 136 10- 139

10-2

10-2

WA1200-6

Contents

Work equipment pump No.2 ................................................................................................ EPC valve (for work equipment) .......................................................................................... Neutral cutoff solenoid valve (NC valve).............................................................................. Relief valve .......................................................................................................................... Accumulator (for EPC valve) ............................................................................................... Work equipment control valve ............................................................................................. Work equipment...................................................................................................................... Work equipment linkage ...................................................................................................... Electrical system ..................................................................................................................... Machine monitor system...................................................................................................... Multi-function monitor .......................................................................................................... Work equipment and AJSS control system ......................................................................... Work equipment control lever .............................................................................................. Transmission control system ............................................................................................... Engine starting circuit .......................................................................................................... Engine stopping circuit......................................................................................................... Electric parking brake control .............................................................................................. Sensor .................................................................................................................................

10- 152 10- 175 10- 177 10- 179 10- 180 10- 181 10- 194 10- 194 10- 196 10- 196 10- 224 10- 277 10- 312 10- 315 10- 341 10- 343 10- 347 10- 357

WA1200-6

10-3

Engine and cooling system Damper

Engine and cooling system

Damper

10-4

10-4

1. Shaft 2. Breather 3. Rubber cushion 4. Inner body 5. Rubber cushion 6. Outer body

10-4 Function q The damper is to relieve the torsional vibration due to the engine's torque change and protect driving system after engine from the torsional vibration. 10-4 Operation 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 between the damper and the torque converter.

10-4

WA1200-6

Engine and cooling system Cooling system

Cooling system

10-5

1. Fan guard 2. Coolant level sensor port 3. Water port 4. Sub-tank 5. Upper tank 6. Hydraulic oil cooler 7. Radiator (LTC) 8. Radiator (HTC) 9. Lower tank

Radiator specifications
LTC Core type Total heat dissipation area(m2) Water passage area(cm2) Modular core 211.6 59,042 HTC Modular core 398.2 88,690

10-5

*LTC: Low Temperature Coolant *HTC: High Temperature Coolant

WA1200-6

10-5

Engine and cooling system Cooling fan motor

Cooling fan motor

Type: LMF40

10-6

P: From fan pump T: To tank from cooler TC: To tank 10-6 Specifications 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

Engine and cooling system Cooling fan motor

1. Output shaft 2. Case 3. Thrust plate 4. Piston assembly 5. Cylinder block

6. Valve plate 7. End cover 8. Center spring 9. Check valve 10. Safety valve

WA1200-6

10-7

Engine and cooling system Cooling fan motor

Hydraulic motor Function 10-8 q This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil sent from the hydraulic pump into rotary motion. 10-8 Principle of operation 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 cylinder block (5) pushes each piston (4) (two or three pistons).
q

10-8

q q

This resultant force [T=s(F3xri)] of torques, as a turning force, rotates cylinder block (5) through piston (4). This cylinder block (5) is connected to output shaft (1) with the spline. Output shaft (1) rotates to transmit the torque.

q q

The force generated per piston: F1 (kg) = P (kg/cm2) x x D2 / 4 (cm2). This force acts on thrust plate (2). AS thrust plate (2) is fixed to output shaft (1) at a certain angle (a), the force is divided into component forces (F2) and (F3).

Radial component forces (F3) of these component forces generates torque (T=F3 x ri) each on (Y-Y) connecting top and bottom dead centers.

10-8

WA1200-6

Engine and cooling system Cooling fan motor

Suction valve Function 10-9 q When the pump stops rotating, the pressurised oil does not flow into the motor. q Since the motor continues to rotate with the force of inertia the pressure on the outlet side of the motor rises. q When the pressurized oil flow stops from inlet port (P), suction valve (1) sucks in the pressurized oil on the outlet side and supplies it to port (MA) where there is not sufficient oil to prevent the occurrence of cavitation. Operation 10-9

10-9 10-9 2) When stopped q When the engine stops, the pump speed becomes 0 rpm. q The pressurized oil from the pump is not supplied to port (P). q Since the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to stop. q If the motor shaft rotates with the inertia force while the pressurized oil flow to port (P) reduces, the pressurized oil in port (T) on the outlet side is sent by suction valve (1) to MA side to prevent 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

Engine and cooling system 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. 10-10 Operation 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 pressurized oil to port (T). q By this operation, the generation of the unusual high-pressure in port (P) is prevented.
q

10-10

10-10

WA1200-6

Power train Power train

Power train
Power train

10-1

10-1

Outline 10-1 q The power of engine (16) is transmitted through engine's flywheel to damper (15). The output shaft of damper (15) is connected through upper drive shaft (14) to modulation clutch (13). The modulation clutch output is connected to the pump of torque converter (11). The torque converter turbine is connected to the input shaft of transmission (10). q The transmission has five hydraulically-actuated clutches and provides three stages of speed for moving forward and reverse respectively, and the speed is selected with electrically controlled switch. q The output shaft of the transmission is connected to the gear of transfer (9) and the power is transmitted to the output shaft. The power is transmitted from the transfer output shaft through center drive shaft (7), center support (34), front drive shaft (6), and rear drive shaft (33) to front axle (5) and rear axle (30), and further is transmitted through wheel to tires.

1. Front differential 2. Front brake 3. Front final drive 4. Front tire 5. Front axle 6. Front drive shaft 7. Center drive shaft 8. Emergency steering pump 9. Transfer (output) 10. Transmission 11. Torque converter 12. Transfer (input) 13. Modulation clutch 14. Upper drive shaft 15. Damper 16. Engine 17. Work equipment pump No.1 18. Work equipment pump No.2 19. Cooling fan pump 20. Switch pump 21. Hydraulic cooling pump 22. Steering pump 23. Control pump 24. PPC pump

WA1200-6

10-11

Power train Power train

25. Torque converter, transmission pump 26. Brake cooling pump 27. Brake pump 28. Rear final drive 29. Rear tire 30. Rear axle

31. Rear differential 32. Rear brake 33. Rear drive shaft 34. Center support 35. Parking brake

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
(input transfer, PTO, modulation clutch, torque converter)

10-15

WA1200-6

10-15

Power train Torque converter

A: To oil cooler B: Torque converter outlet port C: Oil pressure pickup port of torque converter outlet D: To main relief valve E: PTO, input transfer, modulation clutch lubrication port F: Interconnection port G: From transmission pump H: Modulation clutch oil pressure pickup port J: Oil pressure pickup port of torque converter inlet K: Main relief pressure pickup port L: Drain port

1. Mounting location of steering pump, control pump, and PPC pump 2. Switch pump and hydraulic oil cooling pump mounting location 3. Mounting location of transmission charging pump, torque converter charging pump, brake cooling pump, and brake pump 4. Regulator valve of torque converter outlet 5. Work equipment pump mounting location 6. Work equipment pump and cooling fan pump mounting location 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 12. Drive gear (number of teeth: 74) 13. PTO gear (number of teeth: 68) 14. PTO gear (number of teeth: 68) 15. Idler gear (number of teeth: 68) 16. Modulation clutch output shaft 17. Modulation clutch piston 18. Modulation clutch outer drum 19. Modulation clutch inner drum 20. Coupling

21. Torque converter input shaft 22. Drive case 23. Turbine 24. Stator 25. Pump 26. Torque converter case 27. Transmission input shaft 28. Driven gear (number of teeth: 58) 29. Modulation clutch disc 30. Modulation clutch plate

10-18

WA1200-6

Power train Torque converter

Specifications Model: 42C-13-21000 Type: 3-element, 1-stage, 1-phase Stall torque ratio: 2.23 (T3/T1) 2.84(T3/T2)

10-19

WA1200-6

10-19

Power train Torque converter

Operation Power transmitting route

10-20 10-20

10-20

WA1200-6

Power train Torque converter

The torque converter is installed between a damper and a transmission, and the power is transmitted as follows: Engine power O Damper O Universal joint O Coupling (11) O Drive gear (12) O Idler gear (15) O Driven gear (28) O Modulation clutch inner drum (19) O Modulation clutch disc (29), plate (30) O Modulation clutch outer drum (18) O (to upper right)
q

(from lower left) O Modulation clutch output shaft (16) O Coupling (20) O Torque converter input shaft (21) O Drive case (22) and pump (25) rotate together O Oil is used as medium O Turbine (23) O Transmission input shaft (27)
q

The power transferred to coupling (11) is transmitted through drive gear (12), PTO gear (13), and idler gear (15) to the pump as a driving power.

WA1200-6

10-21

Power train Torque converter

Flow of oil

The oil which goes through the main relief valve and whose pressure is adjusted to the set pressure 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 transmission.

10-22

WA1200-6

Power train Torque converter

Modulation clutch Outline 10-23 q The modulation clutch is installed between the input transfer and the torque converter. q It is enabled to change the clutch from complete engagement to slippage by adjusting the clutch oil pressure by using ECMV. q The slipping clutch can reduce the power transmitted to the torque converter.

10-23 10-23 Operation Complete engagement: 10-23 q The oil sent from ECMV (1) for modulation clutch flows through the oil path of modulation clutch case (2) to piston (3) and moves piston (3) rightward. When piston (3) operates and clutch oil pressure 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). 10-23 Slippage: 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 slippage occurs between disc (4) and plate (5), and outer drum (7) rotates slower than inner drum (6). In consequence, the power transmitted is reduced. The power transmitted is determined by the slippage 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 B: To torque converter C: To transmission lubrication circuit D: Drain E: Drain F: Drain G: Drain P1: Oil pressure pickup port at torque converter inlet P4: Main oil pressure pickup port Outline 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) 10-24 Torque converter relief valve The torque converter relief valve is attached to the torque converter inlet circuit so that the oil pressure of torque converter inlet circuit is always 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)

1. Valve body 2. Valve spring (small) 3. Valve spring (large) 4. Main relief valve spool 5. Piston spring 6. Piston 7. Valve spring 8. Torque converter relief valve spool 9. Piston spring 10. Piston 10-24

10-24

WA1200-6

Power train Main relief valve and torque converter relief valve

Operation Operation of main relief valve q The oil from the torque converter charging pump flows through the filter to port A in spool (4), and further flows through orifice a to port B. When the oil from the pump is filled in the circuit, the oil pressure starts to increase.

10-25 10-25 When the oil pressure increases, the oil in chamber B pushes piston (6), and the reaction force compresses valve springs (2) and (3) to move spool (4) leftward and open ports A and C. 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 Main relief valve and torque converter relief valve

10-26 Operation of torque converter relief valve 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 chamber 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).
q

10-26

WA1200-6

Power train Torque converter regulator valve

Torque converter regulator valve

10-27

A: From torque converter B: To oil cooler

1. Valve body 2. Valve spring (small) 3. Valve spring (large) 4. Spool 5. Piston spring 6. Piston 10-27

Outline 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 pressure. Set pressure: 0.88 0.10 MPa {9 1 kg/cm2}

WA1200-6

10-27

Power train Torque converter regulator valve

10-28 Operation 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 tension of valve springs (2) and (3), so spool (4) does not move.

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 pushes piston (6) and the reaction force compresses valve springs (2) and (3) to move spool (4) leftward and ports A and C are opened.

10-28

WA1200-6

Power train ECMV

ECMV

10-29

A: To clutch B: Drain C: From pump P: Clutch pressure measuring port

1. Connector 2. Spring 3. Flow detection valve spool 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 Outline of ECMV 10-30 q ECMV (Electronic Control Modulation Valve) is composed of two valves: pressure control valve and flow detection valve.
q

Pressure control valve

Valve, which converts the current which is sent from the controller and received by the proportional solenoid, into an oil pressure.
q

Flow detection valve

This valve is activated by a trigger from the pressure control valve and has the following functions: 1) Reduces the filling time of the clutch by 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

10-30 10-30 ECMV and proportional solenoid q Single proportional solenoid is installed to each ECMV. The thrust is generated as shown in the figure based on the command current from the controller. The thrust generated in the proportional solenoid is applied to the pressure control valve spool to generate oil pressure as shown in the figure. Thus, the thrust changes by controlling the command current to activate the pressure control valve and control the oil flow and oil pressure.

10-30 ECMV and fill switch 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 Operation of ECMV 10-31 q ECMV is controlled by the command current sent to proportional solenoid from the controller and the fill switch output signal. The following figure shows the relation among the command current to proportional solenoid, the clutch input pressure, and the fill switch output signal. A Range: before gear shift (draining) B Range: filling start (triggering) C Range: filling end D Range: adjusting pressure E Point: filling

10-31 1. Before gear shift (draining) (range A in the

diagram)

When the current does not flow in proportional solenoid (6), the repulsive force of spring (9) for the pressure control valve thrusts back proportional solenoid (6) through pressure control valve spool (7), so pressure control valve spool (7) drains the oil in clutch port C through drain port E. At this time, as the oil pressure does not act on flow detection valve spool (3), flow detection valve spool (3) is put away from fill switch (5) by the repulsive force of fill switch spring (4) and 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

into the pressure control valve) (range B in the diagram)

1) When the trigger current is applied (maximum current is applied) to proportional solenoid (6) while no oil exists in the clutch, proportional solenoid (6) moves to the stroke end to move pressure control valve spool (7) leftward. This opens pump port A and pressure control valve port B and starts to fill the clutch with oil through orifice a of flow detection valve spool (3).

2) At this time, the differential pressure is generated between upstream and downstream sides of orifice a of flow detection valve spool (3). This differential pressure compresses return spring (2) for the flow detection valve and moves flow detection valve spool (3) leftward. Then, flow detection valve spool (3) opens pump port D and the oil flows through orifice a to clutch port C.

10-32

WA1200-6

Power train ECMV

3. When the filling ends (set the pressure control

valve to initial pressure) (range C in the diagram)

1) When pump port D of flow detection valve opens and the oil flows, the differential pressure is generated between upstream and downstream sides of orifice a in flow detection valve spool (3) to push flow detection valve spool (3) leftward. Then, when the current in proportional solenoid (6) is reduced to instantaneous initial pressure level, almost of the pump pressure is applied to load piston (8), so pressure control valve spool (7) is pushed back rightward and a little amount of oil leaks out from pressure control valve port B to drain port E. However, as the amount of this leakage is small, almost of oil from the pump flows into the clutch and flow detection valve spool (3) is pushed leftward.

2) When the clutch is filled with oil, the oil flow from output port B of the pressure control valve to clutch port C stops. As the left and right reception areas of flow detection valve spool (3) are different from each other and the left reception area is larger than the right one. When the oil pressures of both sides are equal to each other, flow detection valve spool (3) moves rightward with the oil pressure. Whereby, the pump port D and clutch port C close. Then, flow detection valve spool (3) compresses fill switch spring (4) because of the area difference between right and left sides and tension of back spring (2) of flow detection valve, and moves rightward to come into contact with fill switch (5) and it is informed to the controller that the clutch finished the filling. In this case, 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 pressure.

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 rightward 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
(transmission, transfer, parking brake)

10-35

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 B: From oil cooler C: Lubricating oil pressure pickup port D: To parking brake E: To modulation clutch ECMV F: To torque converter G: From torque converter case (drain) H: From torque converter case drain J: Suction port

K: From torque converter case drain L: To modulation clutch (lubrication) and input transfer (lubrication) M: From parking solenoid valve N: To transmission lubrication circuit P: To transmission lubrication circuit Q: To 1st clutch R: To 2nd clutch 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 q The transmission is composed of the transmission with "forward 3-speeds, reverse 3-speeds" in combination with the planet gear mechanism and disc clutch, transfer, parking brake, and transmission control valve. q In the transmission single rotation direction and speed are selected by operating two hydraulically engaging clutches out of five pairs of planetary gear mechanism and disc clutch by using a control 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 Forward 1st Forward 2nd Forward 3rd Reverse 1st Reverse 2nd Reverse 3rd Clutch engaged No.2, No.5 No.2, No.4 No.2, No.3 No.1, No.5 No.1, No.4 No.1, No.3

10-39 Operation Operation of clutch 10-39 q In order to lock ring gear (38), piston (36), plate (4), disc (3), pin (41), piston return spring (40), washer spring (42) are used. q The internal teeth of disc (3) are engaged with the outside teeth of ring gear (38). q The projection cut-out portion of plate (4) is engaged with pin (41) fixed to clutch housing (6).

Number of plates and discs used

Clutch No. Clutch No.1 Clutch No.2 Clutch No.3 Clutch No.4 Clutch No.5 Number of plates 7 8 4 3 8 Number of discs 8 9 5 4 9

Clutch engaged (fixed) 10-39 The pressurized oil sent from transmission control valve is supplied through a path in the transmission to the back of piston (36) to move piston (36) leftward. q Piston (36) presses plate (4) and disc (3) to contact each other, and the frictional force stops disc's rotation and locks ring gear (38) engaged with the internal teeth of disc (3).
q

WA1200-6

10-39

Power train Transmission

10-40 Clutch disengaged (released) 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 frictional 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 released, 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.
q

10-40

WA1200-6

Power train Transmission

Power transmitting route Forward 1st

10-41 10-41

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 clutch ring gear (13) O 2nd carrier, 1st clutch drum (24) O 1st clutch hub (25) O Output shaft (22)

3rd sun gear (29) O O O

WA1200-6

10-41

Power train Transmission

Forward 2nd

10-42

Forward ring gear (9) in the forward clutch and 2nd ring gear (18) 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 clutch ring gear (13) O 2nd carrier, 1st clutch drum (24) O 2nd Planetary pinion (16) O 2nd sun gear (26) O Output shaft (22)

3rd sun gear (29) O O O O

10-42

WA1200-6

Power train Transmission

Forward 3rd

10-43

Forward ring gear (9) in the forward clutch and 3rd ring gear (13) in the 3rd clutch 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 Output shaft (22)

WA1200-6

10-43

Power train Transmission

Reverse 1st

10-4

Reverse ring gear (38) in the reverse clutch and 1st clutch hub (25) are engaged by using an oil pressure.
Power from torque converter 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 3rd clutch planetary pinion (12) O 3rd clutch ring gear (13) O 2nd carrier, 1st clutch drum (24) O 1st clutch hub (25) O Output shaft (22)

3rd sun gear (29) O O 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 Transmission control valve

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 Gear speed In automatic Neumode tral In manual (N) shift mode Forward 1st (F1) Forward 2nd (F2) Forward 3rd (F3) Reverse 1st (R1) Reverse 2nd (R2) Reverse 3rd (R3) No.1 No.2 Clutch No.3 No.4 Q Q Q Q Q Q Q Q Q Q Q No.5

Q Q Q

Q Q

In neutral manual position, the clutch is engaged in the gear shift where the gear shift lever is located.

WA1200-6

10-47

Power train Transmission control valve

10-48 Bypass fill valve 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 The bypass fill valve is controlled by the command 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 Transmission control valve

Operation 10-49 When the solenoid valve is de-energized 10-49 q As spool (2) in solenoid valve (1) is pushed rightward 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.

10-49 When the solenoid valve is energized 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 pressurized oil, ports P and C are opened, and the oil from the pump is supplied to the clutch.

WA1200-6

10-49

Power train Transmission control valve

Bypass drain valve Outline 10-50 q When the clutch is disengaged, the oil in the clutch piston is drained through ECMV into the transmission case. When the clutch's piston volume is large, if ECMV only is operated as usual, it takes some time to discharge oil. When next gear shift starts before the discharge is finished, a shock may occur. 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. 10-50 Operation When the solenoid valve is de-energized (in nor10-50 mal condition) q As spool (2) in solenoid valve (1) is pushed rightward 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 C and T are closed.

10-50 When the solenoid valve is energized (discharg10-50 ing clutch oil) q When current flows in solenoid valve (1), spool (2) is pushed leftward, so port P and chamber A open and the pressurized oil is supplied to chamber A. Thus, spool (4) is moved leftward by the pressurized oil, ports C and T are opened, and the oil from the pump is drained.

This valve works for a certain period of time immediately after the clutch is changed from the engaged condition to the disengaged condition. Thus, this valve does not work in normal cases (a certain period of time gone by from adjusting clutch pressure, filling clutch, or clutch OFF).

10-50

WA1200-6

Power train Transmission control valve

ECMV (for transmission)

10-51

A: To clutch B: Drain C: From pump P: Clutch pressure measuring port

1. Connector 2. Spring 3. Flow detection valve spool 4. Spring 5. Fill switch 6. Proportional solenoid 7. Pressure control valve spool 8. Load piston 9. Spring

WA1200-6

10-51

Power train Transmission control valve

Outline Outline of ECMV 10-52 q ECMV (Electronic Control Modulation Valve) is composed of two valves: pressure control valve and flow detection valve.
q

Pressure control valve

Valve, which converts the current which is sent from the transmission controller and received by the proportional solenoid it into an oil pressure.
q

Flow detection valve

This valve is activated by a trigger from the pressure control valve and has the following functions: 1) Closes the valve as soon as oil fills in the 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

10-52 10-52 ECMV and proportional solenoid q Single proportional solenoid is installed to each ECMV. The thrust is generated as shown in the figure based on the command current from the transmission controller The thrust generated in the proportional solenoid is applied to the pressure control valve spool to generates oil pressure as shown in the figure. Thus, the thrust changes by controlling the command current to activate the pressure control valve and control the oil flow and oil pressure.

10-52 ECMV and fill switch 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 Transmission control valve

Operation Operation of ECMV 10-53 q ECMV is controlled by the command current sent to proportional solenoid from the transmission controller and the fill switch output signal. The following figure below shows the relations among the command current to proportional solenoid, the clutch input pressure, and the fill switch output signal. A Range: before gear shift (draining) B Range: filling start (triggering) C Range: filling end D Range: adjusting pressure E Point: filling

10-53 1. Before gear shift (draining) (range A in the

diagram)

When the current does not flow in proportional solenoid (6), the repulsive force of spring (9) for the pressure control valve thrusts back proportional solenoid (6) through pressure control valve spool (7), so pressure control valve spool (7) drains the oil in clutch port C through drain port E. At this time, as the oil pressure does not act on flow detection valve spool (3), flow detection valve spool (3) is put away from fill switch (5) by the repulsive force of fill switch spring (4) and stands still in the position where it balances with return spring (2) of the flow detection valve.

WA1200-6

10-53

Power train Transmission control valve

2. When the filling starts (trigger command is input

into the pressure control valve) (range B in the diagram)

3. When the filling ends (set the pressure control

valve to initial pressure) (range C in the diagram)

When the trigger current is applied (maximum current is applied) to proportional solenoid (6) while no oil exists in the clutch, proportional solenoid (6) moves to the stroke end to move pressure control valve spool (7) leftward. This opens pump port A and pressure control valve port B open and starts to fill the clutch with oil through orifice a of flow detection valve spool (3).

1) After a certain period of time, the flow rate of oil for filling the clutch is dropped down by reducing the current value of proportional solenoid (6) to an initial pressure level, moving pressure control valve spool (7) rightward, and throttling the path between pump port A and pressure control valve port B. This enabled to prevent the occurrence of peak pressure in clutch port C when the filling ends and change the gear shift smoothly.

10-54

WA1200-6

Power train Transmission control valve

2) When the clutch is filled with oil, the oil flow stops from output port B of the pressure control valve to clutch port C. As the right and left reception areas of flow detection valve spool (3) are different from each other and the left reception area is larger than the right one, when the oil pressures of both sides are equal to each other, flow detection valve spool (3) moves rightward with the oil pressure. At this time, flow detection valve spool (3) compresses fill switch spring (4) based on the area difference between right and left 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 pressure.

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 rightward by the difference between the oil pressures applied on both sides to continue to output the fill signal to the controller.

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 10-56 Function q The translation lubricating oil relief valve is installed 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 10-57 Outline 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 Power transmitting route

10-58 10-58

The power from transmission output shaft (1) is transmitted as follows:

Transmission output shaft (1) O Transfer input gear (2) O Transfer idler gear (3) O Transfer output gear (4) O (to upper right)

(from lower left) O Output shaft (5) O Center drive shaft O Front drive shaft O Front axle

O O Rear drive shaft O Rear axle

10-58

WA1200-6

Power train Torque converter oil cooler

Torque converter oil cooler

10-59

1. Torque converter oil cooler A. Oil inlet port (from torque converter regulator valve) B. Oil outlet port (to transmission lubrication) C. Water inlet port (from water pump) D. Water outlet port (to engine block)

10-59 Outline q The torque converter oil cooler is installed on the bottom of the engine oil pan. The oil output from the torque converter is at a high temperature due to the power train energy. This torque converter oil enters through oil cooler port A into the oil 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 2. Case 3. Grease nipple 4. Rear coupling

Function 10-60 q The center support is installed on the front frame between center and front drive shafts q In the case of the articulate frame, this part always 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
Front axle

10-61
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

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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

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Power train Axle

Outline 10-65 q The power from the engine is transmitted through the damper, upper drive shaft, modulation clutch, torque converter, transmission, and drive shaft to the front and rear axles. q In the axle, the power is transmitted from pinion gear (1) to bevel gear (5), then the transmission of the power changes 90 degrees in direction, reduces speed, and is transmitted through differential (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.

10-65 At straight-travel q When traveling straight, the speeds of right and left wheels are the same, so pinion gear (4) in differential Ass'y does not rotate, but the power of carrier (6) is evenly transmitted through pinion gear (4) and side gear (3) to right and left axle shafts (2).

10-65 At swing 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) according to the difference between right and left speeds.

WA1200-6

10-65

Power train Final drive

Final drive

10-6

1. Axle shaft 2. Brake 3. Ring gear (number of teeth: 81) 4. Ring gear (number of teeth: 76) 5. Sun gear (number of teeth: 21) 6. Sun gear (number of teeth: 28) 7. Drain plug 8. Planetary gear (number of teeth: 23) 9. Planetary gear (number of teeth: 29) 10. Housing 11. Wheel 12. Thrust spacer 13. Plate 14. Shaft

10-6 Outline q In order to get large driving force, the final drive reduces the speed and transmits the driving force to the wheels by utilizing the planetary gear mechanism. q The power transmitted from the differential through axle shaft (1) to 1st sun gear (5) is transmitted to planetary gear (9), and as the planetary gear rotates in the fixed ring gear (3), the power is transmitted to 2nd sun gear (6). Similar to 1st sun gear, decelerated rotation travels to the planetary gear and the power is transmitted to wheel (11) mounted on the carrier.

10-66

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Steering system Steering equipment layout drawing

Steering system

Steering equipment layout drawing

10-67

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

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10-67

Steering system AJSS

AJSS
* AJSS: Advanced joystick steering system a For information on the operation, refer to the section "Work equipment, AJSS controll system"

10-68

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
Model: HPV160 + 160 + SAR(2)71 + +63

10-70

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 PAD2: 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 PGS2: 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
Model: HPV160 + 160 + SAR(3)125 + 100

10-72

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. PAD1: Gear pump discharge port PAD2: 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 PGS2: 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 cooling pump (SAR(3) 125) 6. Hydraulic cooling pump (SAR(3) 100)

WA1200-6

10-73

Steering system Switch pump

Model: HPV160 + 160 pump Outline q The piston pump model for the steering pump and switch pump is HPV160 + 160, and the same pump is used.

10-74 10-74

10-74

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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 The engine rotation torque transmitted to the pump shaft is converted into the hydraulic pressure 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.
q

10-76 Structure 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 sliding in a circular pattern. q Rocker cam (4) conducts high pressure oil to cylinder surface (B) contacted with cradle (2), which is secured to the case, and forms a static pressure bearing when it slides. q Piston (6) performs the reciprocation axially inside 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).
q

10-76

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Steering system Switch pump

Operation of pump q Cylinder block (7) rotates along with shaft (1) and shoe (5) slides on plane (A). q Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of rocker cam (4) and the axis of cylinder block (7) changes. q Angle (a) is called the swash plate angle.

10-7 When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is 0), the difference between volumes (E) and (F) inside in cylinder block (7) is zero. Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not performed. (Actually, however, a zero swash plate angle never occurs.)

q 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). Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder block (7). Each piston (6) sucks and discharges oil by (F) (E). If cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from chamber (E) during this process. 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

10-78 Control of delivery When swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and delivery (Q) also increases. q Swash plate angle (a) is changed with servo piston (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 receiving 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 diameter piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas where receiving the pressure of the small diameter piston and large diameter piston.
q

10-78

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Steering system Switch pump

1. LS valve

10-79

PA: Pump port PDP: Drain port PLP: LS control pressure output port PLS: LS pressure input port PP: Pump port PPL: Control pressure input port PSIG: Drain port 10-79 Function 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) [=(PPPLS)], and delivery (Q).

1. Sleeve 2. Piston 3. Spool 4. Spring 5. Seat 6. Sleeve 7. Plug 8. Locknut

WA1200-6

10-79

Steering system Switch pump

Operation 1) When control valve is in NEUTRAL position:

10-80 10-80

q q

q q q

The LS valve is a 3-way selector valve, and pressure (PLS) LS pressure from the control valve inlet is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port (H) of sleeve (8). 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). Before the engine is started, servo piston (12) is pushed to the left. (See the figure on the right) 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) Spool (6) is pushed to the right, and port (C) and port (D) are connected. Pump pressure (PP) is transmitted to the larger diameter end of the pump from the port (K). The same pump pressure (PP) is transmitted to the smaller diameter end of the pump at the port (J).

By the area difference of servo piston (12), the servo piston moves in such a direction that the swash plate angle is minimized.

10-80

WA1200-6

Steering system Switch pump

2) Move to increase the pump delivery:

10-81

q 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 increases 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. When spool (6) moves, ports (D) and (E) are connected to each other and to the PC valve. Since the PC valve and drain port are connected, the pressure between circuits (D) and (K) becomes drain pressure (PT). (PC valve operation will be explained later.) The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and pump pressure (PP) is constantly applied to port (J) on the small diameter side. Accordingly, servo piston (12) is pushed to the left and the swash plate is moved to increase the delivery.

WA1200-6

10-81

Steering system Switch pump

3) Move to decrease the pump delivery:

10-82

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. The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston through port (C), port (D) and port (K). Though pump delivery pressure (PP) enters the small diameter piston port (J), because of the area difference between the large diameter piston 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

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Steering system Switch pump

4) When servo piston is balanced:

10-83

The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of the piston, the area receiving the pressure at the small diameter end and the pressure conducted to the large diameter end of the piston, respectively. When the force exerted by main pump pressure (PP) of the LS valve is balanced with the combined 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. The swash plate of the pump is held in intermediate 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)] 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.

The force of spring (4) is adjusted so that spool (6) is balanced at this position when (PP - PLS) =1.37 MPa {14 kg/cm2} at the center based on the standard.

WA1200-6

10-83

Steering system Switch pump

2. PC valve

10-84

PA: Pump port PA2: Pump pressure pilot port PDP: Drain port PPL: Control pressure output port (to LS valve)

1. Plug 2. Servo piston assembly 3. Pin 4. Spool 5. Retainer 6. Seat 7. Cover 8. Wiring 10-84

Function 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 decreases the pump delivery. q And if the pump delivery pressure goes low, it increases the pump delivery. q In this case, the figure on the right shows the relation 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 (1) When load to actuator is small and pump pressures (PP1), (PP2) are low

10-85 10-85

Spool (2) stops at the position where the combined 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 pressure 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.
q

WA1200-6

10-85

Steering system Switch pump

Action of spring The spring load of spring (3) is determined for PC valve according to the position of the swash plate. q As servo piston (4) moves to the right spring (3) is compressed. q Servo piston (4) changes the spring load by extending or compressing spring (3). q Port (C) of the PC valve is connected to port (E) of the LS valve. q Self pressure (PP1) enters into the small diameter piston side of servo piston (4) and port (B), and other pump pressure (PP2) enters into port (A). 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 becomes 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.
q

q q

Spring (3) extends according to the movement of servo piston (4) to reduce the spring force. When the spring force is reduced, spool (2) moves to the right, ports (C) and (D) are shut off, and port (B) with pump delivery pressure is connected to port (C). As the pressure of port (C) increases and the pressure of larger piston side increases, the movement to the left of servo piston (4) stops. The stop position (= pump delivery) of servo piston (4) is determined when the force caused by pressures (PP1)and (PP2) applied to spool (2) and the force of spring (3) are balanced.

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 q When a load is large and pump delivery pressures (PP1)and (PP2) are high, the force to push spool (2) to the right increases, and spool (2) is in the position shown in the figure above. q As a part of pressure from port (B) flows through LS valve and port (C) into port (D), as shown in the figure above, the pressure flowing from port (C) into LS valve becomes about a half of pump pressure (PP2). 10-87 Operation q When ports (E) and (G) of LS valve are connected to each other, this pressure from port (J) enters into large diameter piston side in servo piston (4) to stop servo piston (4). q When pump pressures (PP1) and (PP2) increase further, and spool (2) moves rightward, pump pressure (PP1) is transmitted to port (C), and this moves piston (4) so that the pump delivery decreases to minimum. q When servo piston (4) moves to the right, spring (3) is compressed to push back spool (2).

q q q

10-87 When spool (2) moves to the left, the opening of ports (C) and (D) increases further. The pressure (= J) of port (C) decreases, and the movement to the right of servo piston (4) stops. At this time, servo piston (4) stops at the further right position than that when pump pressures (PP1) and (PP2) are low. The bent line graph shows the positional relations between average pump pressure (PP1 + PP2)/2 and servo piston (4). The relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q) is shown below.

WA1200-6

10-87

Steering system Switch pump

10-88

WA1200-6

Steering system Steering demand valve

Steering demand valve

10-89

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10-89

Steering system Steering demand valve

1. Overload 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)

Main relief valve

1. Adjustment screw 2. Spring 3. Plug 4. Pilot poppet 5. Valve seat 10-90 Function q The main relief valve of the steering demand valve exists in the valve and sets up the maximum pressure of the steering circuit while the steering is in operation. That is, when the pressure in the steering circuit becomes or exceeds the set pressure of the valve during the valve operation, 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 Steering demand valve

Function 10-91 q The overload relief valve is installed in the cylinder circuit of the steering demand valve. When 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 cylinder or hydraulic piping by relieving the pressure through this valve and the function which prevents a vacuum when negative pressure occurs in the cylinder. 10-91 Operation 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 diameters d1 and d2 to securely seat check valve poppet (3) and relief valve poppet (2).

When pilot poppet (4) opens, the pressure on the back of poppet (1) decreases, and poppet (1) moves rightward to seat on pilot poppet (4).

As the inside pressure is lower compared with the pressure of port A, the relief valve poppet (2) opens. The oil flows from port A into port B to prevent unusual pressure.

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 port B.

10-91 2. Action of suction valve When a negative pressure occurs in port A, because of the difference between the areas of diameters 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 Steering demand valve

Action of steering relief valve

10-92

When the circuit pressure increases to the pressure set by adjust screw (1) and spring (2), pilot poppet (3) opens to drain the oil. Here, the pressures of chamber receiving pressure (I) and chamber receiving pressure (II) are not balanced, and the flow control spool (4) moves leftward.

The movement of the flow control spool (4) prevents the pressure in the steering circuit from exceeding the specified value by draining the oil of steering pump and flowing the oil of the switch pump into the main control valve.

LS load sensing port 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 Steering demand valve

Action of demand valve When the steering spool is in neutral

10-93 10-93

q q

The oil from the steering pump enters into port A. The oil from the switch pump enters into port B. When steering spool (2) is in neutral, pressure receiving chamber (II) connects through orifice b to the drain circuit, and notch c is closed. As notch c is closed, the oil in ports A and B increases in pressure and goes through orifice a into pressure receiving chamber (I) to move flow control spool (1) leftward. When the pressure of pressure receiving chamber (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 Steering demand valve

When operating steering control valve Engine running at low speed

10-94

When the steering is operated, the oil flows from the rotary valve to steering spool (2) to push steering spool (2) rightward, shut off pressure receiving chamber II and drain circuit, and open notch c. Thus, the pressure in pressure receiving chamber II increases, flow control spool (1) moves rightward until notch h closes. The path from port B to the main control valve is shut off, the oil in the switch pump opens merge-divider check valve (4) to merge with the oil from steering pump in port A. 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.

Here, the pressure before passing through notch c is led into pressure receiving chamber I and the pressure after passing through notch c is led into pressure receiving chamber II. And flow control valve spool (1) works so that the difference between the pressures before and after notch c is always maintained constant. Therefore, the flow rate of oil is supplied to the cylinder port according to the opening of notch c. These pressure differences (control pressures) are set up by spring (3).

10-94

WA1200-6

Steering system Steering demand valve

When engine is running at high speed

As the backup oil from the switch pump is not required, the steering pump pressure rises until notch g closes and the merge path of port B is shut off. 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.) 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. As notch g is closed, all the oil from the switch pump flows through port B and enters into the main control valve. 10-95

WA1200-6

Steering system Steering demand valve

Action of steering valve NEUTRAL

10-96 10-96

q q q

Because the steering wheel is not activated, steering spool (2) does not move. The oil from the steering pump enters into port A. The oil from the switch pump enters into port B. 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 Steering demand valve

Right turn

10-97

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 Steering demand valve

Left turn

10-98

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 steering 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 machine 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

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Steering system Rotary valve

Rotary valve

10-9

1. Neutral position spring 2. Valve body 3. Check valve 4. Spool 5. Sleeve 6. Feedback spool 7. Feedback sleeve 8. Loose spring 9. Drive shaft 10. Center pin 11. Body

a. To hydraulic tank b. To steering demand valve Pb port c. To steering demand valve Pa port d. From PPC pump

WA1200-6

10-99

Steering system Rotary valve

Outline 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 machine. This always matches the position of the steering control lever with the position of machine steering.
q

10-10

10-10 Structure Spool (4) connects to sleeve (5) by using pin (10) and neutral position spring (1) (When the steering 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 coupled 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 respectively.
q

10-100

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Steering system Rotary valve

Operation q As the steering control lever is operated, rotate spool (4) rotates against sleeve (5) by overcoming 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 displacement via drive shaft (9). q When the oil flows into the steering cylinder and the steering of the machine starts, the link installed on the front frame makes sleeve (5) rotate 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.

10-101

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 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 proportional solenoid valve fails because of a failure in the controller system. 10-102

10-102

WA1200-6

Steering system Diverter valve

Diverter valve

10-103

1. Check valve 2. Check valve 3. Check valve 4. Check valve 5. Spool 6. Valve body

A. To emergency pump B. Sensor mounting port C. To hydraulic tank D. To steering valve E. From hydraulic tank F. From steering circuit

Function 10-103 q When the steering is inoperable due to the engine stop, pump seizure, etc. while the machine is traveling, the valve enables the steering operation by driving the emergency pump by using the rotating movement in the transmission.

WA1200-6

10-103

Steering system Diverter valve

Operation When pump and engine are normal

10-104

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 operable by sending the oil to the steering valve. Also, the emergency pump is driven by the transmission, 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

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 rotation 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 direction, forward or reverse.

WA1200-6

10-105

Steering system Emergency steering relief valve

Emergency steering relief valve

q

10-106
When the pressures in ports A and B reach to the set force (set pressure) of poppet spring, pilot 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

10-106 Function q As the rated pressure of both emergency steering pump and diverter valve is 20.6 MPa {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 operate. 10-106 Operation 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).

When the pressure in port B decreases, the orifice in main valve (1) causes differential pressure between ports A and B, the pressure in port A opens main valve (1) to release the oil in port A.

10-106

WA1200-6

Steering system Steering lock valve

Steering lock valve

10-107

1. Steering lock lever 2. Steering lock valve Assy 3. Lever 4. End cap 5. Ball 6. Seat 7. Body 10-107 Outline 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

Brake equipment layout drawing

10-108

10-108

1. Front brake (right) 2. Brake valve (right) 3. Parking brake switch 4. Rear brake (right) 5. Slack adjuster (rear) 6. Torque converter, transmission, brake cooling, brake pump 7. Rear brake (left) 8. Brake tank 9. Parking brake (with built-in transmission) 10. Accumulator

11. Brake valve (left) 12. Front brake (left) 13. Slack adjuster (front) 14. Charge valve 15. Strainer 16. Parking brake solenoid valve 17. Check-valve Ass'y of parking brake circuit

10-108

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Brake system Brake valve

Brake valve
Brake valve (right)

10-109

1. Brake pedal (right and left brakes) 2. Rod (right brake) 3. Pilot piston (right brake) 4. Spool (right brake) 5. Upper cylinder (right brake) 6. Spool (right brake) 7. Lower cylinder (right brake) 8. Rod (left brake)

9. Spool (left brake) 10. Cylinder (left brake) A. Pilot port (right brake) B. To rear brake (right brake) C. To front brake (right brake) D. Drain (right and left brakes) E. To pilot port (left brake)

WA1200-6

10-109

Brake system Brake valve

Brake valve (left)

Outline 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.
q

10-1 0

10-110

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Brake system Brake valve

Operation When brake is activated (right brake valve) Upper part 10-1 1 q When pedal (1) is depressed the depressing effort 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. 10-1 1 Lower part When pedal (1) is depressed the depressing effort 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.

10-1 1 10-1 1

1 2

3
Dr a i n

4
C

a
A c c u mu l a t o r

A
F r o mp u mp A c c u mu l a t o r Tor ear br ak e c y l i nder

5
F r o mp u mp

6
Tof r ont br ak e c y l i nder

A 4 W1 1 4 5 1

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10-111

Brake system Brake valve

When the brake is activated (left brake valve) 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 accumulator 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 orifice d into port G to push pilot piston (11) and push down spool (3) through a spring, similarly when right brake valve is treadled.
q

10-1 2

10-112

WA1200-6

Brake system Brake valve

Brake operation when upper valve fails (right 10-1 3 brake valve) q Even if the oil leaks in the upper piping, moved down by depressing pedal (1) spool (5) is mechanically. The lower valve works properly. The upper brake does not work. Brake operation when lower valve fails (right 10-1 3 brake valve) q Even if the oil leaks in the lower piping, the upper part works properly.

10-1 3 Lower part Spool (3) moves upward in the upper part and the path between ports A and C is shut off, and at the same time, the oil is filled in the front brake cylinder, the oil pressure increases between ports B and D, and the oil entered through orifice f in spool (5) into port J pushes up spool (5) by the same amount as the moving amount of the spool (3) to shut off ports B and D. Also, as the drain port b is closed, the oil entered into the 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 pressure 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 between 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 pressure from the pump. Therefore, until the piston travels in the full stroke, the effect of the brakes can be adjusted by depressing the pedal.
q

10-1 3 When brake works with balance 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

10-1 4 When brake is released (right brake valve) 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 release drain port a, and the oil from the brake cylinder flows into the return circuit to the hydraulic tank and the rear brake is released. 10-1 4 Lower part 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 released.

10-114

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Brake system Charge valve

Charge valve

10-1 5

ACC: Plug PP: To brake valve P: From pump T: To brake oil tank

Function 10-1 5 q The charge valve works so that the oil pressure from the pump can be maintained in the specified 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

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Brake system Charge valve

Operation 1. When the oil is not supplied to the accumulator (cutout condition) q As the pressure of port B is higher than the set pressure of relief valve R1, the oil pressure of port B pushes piston (8) upward forcibly to open poppet (6) and make a short out between ports C and T. q As the rightmost spring chamber in spool (15) leads to port C in relief valve R1, the pressure is the same as the one in the tank. The oil from the pump enters into port P to push spool (15) rightward with low pressure corresponding to the load of spring (14) and flows in the tank through orifices (17), (18), (16).

10-1 7 2. When oil is supplied to the accumulator 1) cutin condition q When the pressure in port B is less than or equal to the set pressure of relief valve R1, piston (8) is pushed back downward by spring (5). As a result, valve seat (7) comes into tight contact with poppet (6) and port C is shut off from port T. q The right spring chamber in spool (15) is shut off from port T, so its pressure increases, and similarly, the pressure of port P increases. q When the pressure of port P reaches the pressure of port B (accumulator pressure) or higher, the oil supply starts to the 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 regardless of the engine speed.

WA1200-6

10-117

Brake system Charge valve

2) When the pressure reaches to cutout pressure q When the pressure of port B (accumulator pressure) reaches to the set pressure of relief valve R1, poppet (6) gets away from valve seat (7), the oil flows to start a relief operation. 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.

3. Main relief valve (R3) When port P (pump pressure) reaches the set pressure of relief valve R3 or higher, the oil from the pump pushes up pole (11) against spring (3) to lead the oil into the tank circuit so that the maximum pressure in the brake circuit is regulate and the circuit is protected.

10-118

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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 10-1 9 Function q There are two types of accumulators, (1) and (2). The accumulators are installed between each charge valve and brake valve, and absorb the pulsation of hydraulic pump and secure the braking force and operability while the engine stops by filling the nitrogen gas between cylinder (6) and free piston (7) and using the compressibility of it. 10-1 9 Specifications Gas used: nitrogen gas Gas capacity: Accumulator (1): 20 l Accumulator (2): 3.5 l Charge pressure: Accumulator (1) : 11.8 0.49 MPa {120 5 kg/cm2} Accumulator (2) : 10.7 0.34 MPa {109 3.5 kg/cm2}

WA1200-6

10-119

Brake system Slack adjuster

Slack adjuster

10-120

1. Bleeder 2. Cylinder 3. Check valve 4. Piston 5. Spring A: Inlet port B: Outlet port

10-120 Specifications q Piston operation oil pressure: 0.01(+0.001/0) MPa {0.1 (+0.01/0) kg/cm2} q Check valve cracking pressure: 1.740.05MPa {17.8 0.5 kg/cm2} q Check valve closing pressure: 1.090.05MPa {11.1 0.5 kg/cm2} 10-120 Function 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 constant 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 adjuster into right and left cylinders (2) to move piston (4) rightward and leftward by stroke S.

Whereby, brake piston (7) moves by stroke S. At this time, the relation between the brake piston and disc is that the clearance becomes zero, but the brake force does not occur.

10-121 2. When brake pedal is released 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 constant regardless of the wear amount.

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 2. Brake piston 3. Return spring 4. Floating seal 5. Disc 6. Plate 10-12 Function q The service brake is installed in four wheels and has wet multiple disc structure.

10-12 Operation q When the brake pedal is depressed brake piston (2) moves to the right to contact and lock disc (5) and plate (4) closely. As disc (5) is rotating along with the wheel, the rotation stops by the lock, the brake is applied, and the machine stops. When the brake pedal is released the back pressure of piston (2) is released. The piston moves to the left with the force of return spring (3) to release the brake.

10-122

WA1200-6

Brake system Parking brake

Parking brake

10-123

A. Piston room 1. Rear coupling 2. Output shaft 3. Spring 4. Piston 5. Disc 6. Plate 7. Front coupling

10-123 Outline q The parking brake is a wet multiple disc brake which is activated mechanically by using spring (3) to apply brake to output shaft (2) of the transmission. q The braking operation is made by pressing disc (5) and plate (6) with piston (4) by using the tension of spring (3). By the operation output shaft (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 2. Block B. Outlet port P. Inlet port (from transmission) T. Drain port

10-124 Outline q By the operation of the parking brake switch to turn it ON or OFF, the solenoid valve is energized or de-energized. It leads the pressurized oil to the parking spring cylinder or cancels the supply of the pressurized oil, that results the machine in the condition that the parking brake is applied or not. q Energizing the parking brake solenoid valve: Traveling De-energizing: Parking

10-124

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Brake system Emergency parking brake release valve

Emergency parking brake release valve

10-125

10-125 Operation q when the parking brake emergency release switch (1) is turned ON solenoid valve (2) is activated. The oil pressure stored in the accumulator (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 Assy 2. Solenoid valve A: To parking brake B: From parking brake solenoid valve C. From transmission T. Drain P. From brake (accumulator circuit) 10-125 Function 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

Function q When the transmission gear is shifted, a large amount of oil flows into the clutch in the transmission instantaneously and the oil pressure decreases in the parking brake circuit for a moment. q When the parking brake oil pressure decreases to the engagement pressure or less, the parking brake is engaged to lock the parking brake for a moment.

10-126
10-126 a This locking of parking brake is only for a moment and does not have any affect on the operation of the machine. The operator also finds no problem. q The check valve of parking brake circuit is installed between the main transmission and parking brake circuits and prevents the oil pressure from decreasing for a moment in the parking 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 Check valve of parking brake circuit

Operation 1. When parking brake is released (ON o OFF operation) q When the parking brake switch is turned OFF, the parking brake solenoid valve is energized, 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 Assy of the parking brake circuit compresses spring (2) leftward 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.

10-127 [Reference] Cracking pressure of check valve assembly for parking brake circuit: 9.4 kPa {0.096 kg/cm2}

2. While parking brake is released q While the parking brake is released, the oil pressures of ports A and B are equal to each 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 circuit 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 Assy in the parking brake circuit 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 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 Assy 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 transmission circuit A. q Therefore, oil pressure B in the parking brake circuit is protected from the drop of oil pressure A in the main transmission circuit.

WA1200-6

10-127

Brake system Check valve of parking brake circuit

4. When parking brake is activated (OFF o ON operation) q When the parking brake switch is turned ON, the parking brake solenoid valve is energized, the circuit which leads oil pressure A in the main transmission circuit to the parking brake spring cylinder closes and the drain circuit in the parking brake spring cylinder opens. q When the pressurized oil in the parking brake spring cylinder is drained, the parking brake is activated by the parking brake spring force. q As the oil pressures of ports A and B in the check valve Assy of the parking brake circuit are equal to each other, valve (1) is pressed rightward by the tension of spring (2) to close port C.

5. When engine is stopped q When the engine is stopped, the supply of oil pressure A to the main transmission circuit is stopped. q As this time, port C is still closed and in parking brake circuit B between the check valve Assy of the parking brake circuit and parking brake solenoid valve, the oil pressure is in the main transmission circuit A before the engine stoppage is kept. k When removing a hose in the parking brake circuit, be careful because the oil pressure remains inside even when the engine is stopped. (Loosen the hose fitting a little, fully release internal oil pressure, and then disconnect the hose.)

10-128

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Undercarriage and frame Axle mount

Undercarriage and frame

Axle mount

10-129

10-129

WA1200-6

10-129

Undercarriage and frame Axle mount

1. Front frame 2. Rear frame 3. Rear axle 4. Front axle 5. ROPS support

Front axle q Because the front axle directly receives the force during the work, the front axle is directly fixed to the front frame with tension bolts. Rear axle 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

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Undercarriage and frame Center hinge pin

Center hinge pin

10-131

1. Front frame 2. Rear frame 3. Rear axle

4. Front axle 5. Upper hinge pin 6. Lower hinge pin

Outline 10-131 q The front frame and rear frame are connected with each other through bearings by the center 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

Undercarriage and frame Jack-up point

Jack-up point

10-132

1. Front frame (lower left of lift arm cylinder mount) 2. Front frame (lower right of lift arm cylinder mount) 3. Rear frame (lower left of center hinge) 4. Rear frame (lower right of center hinge) 5. Rear bumper (lower left of rear bumper) 6. Rear bumper (lower right of rear bumper)

10-132 Outline q To jack up the machine replacing a wheel, attach the jacks to the front frame (bottom of lift arm cylinder mount), rear frame (bottom of center hinge), and bottom of rear bumper. q The jack up point is not indicated in the Operation and Maintenance Manual because it is dangerous to jack up the machine unnecessarily.

10-132

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Hydraulic system Hydraulic piping layout drawing

Hydraulic system

Hydraulic piping layout drawing

10-13

10-13

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10-133

Hydraulic system Hydraulic piping layout drawing

1. Bucket cylinder 2. EPC valve 3. Work equipment control lever 4. Work equipment pump 4A. Work equipment pump 1 4B. Work equipment pump 2 5. Switch pump 6. Accumulator 7. Oil cooler 8. Steering pump 9. Transmission (with transfer) 10. Lift arm cylinder 11. Work equipment valve (3 pcs)

10-134 Outline q The hydraulic system is composed of work equipment and steering circuits, and the work equipment circuit controls the operation of the bucket (and attachment). q The oil in the hydraulic tank is sent through work equipment pumps (4A), (4B), switch pump (5), and the steering valve to three work equipment valves (11). When respective spools for bucket and lift arm in the work equipment control valve are in neutral, the oil passes through the drain circuit in the work equipment control valve and is filtered by the filter in the hydraulic tank and returns to the hydraulic tank. q When work equipment control lever (3) is operated, 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 equipment 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, pressure is applied to the tank, negative pressure is prevented, and the cavitation in the pump is prevented. 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

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Hydraulic system Work equipment control lever linkage

Work equipment control lever linkage

10-135

1. Bucket lever knob 2. Lift arm lever knob 3. Kickdown switch 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

9. R.H. console forward-reverse slide lever 10. Armrest adjustment lever 11. Armrest

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10-135

Hydraulic system Hydraulic tank

Hydraulic tank

10-136

1. Strainer 2. Oil filler port 3. Oil filler port strainer 4. Filter bypass valve 5. Filter 6. Breather 7. Cleaner 8. Drain valve A. Oil cooler return port B. Steering oil return port C. Loader oil return port D. Emergency steering oil return port E. Main suction port F. Emergency steering oil suction port G. PPC, PV control, cooling oil suction port

10-136 Outline q The oil sent into each cylinder through the work equipment control valve from the hydraulic tank using the pump merges with oil from each part in the return circuit. A part of the oil is cooled by the oil cooler and filtered with the oil filter to return into the hydraulic tank. q This oil filter filters whole oil in the return circuit from the work equipment control valve. When the oil filter is clogged, the bypass valve is activated to move the oil back directly to the tank and prevent the filter from being damaged. Also, the bypass valve is activated when negative pressure is generated in the circuit. q Strainer (1) is installed in the suction port of the hydraulic tank.

10-136

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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}

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} 10-138 Function 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

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Hydraulic system Work equipment pump No.1

Work equipment pump No.1

Model: HPV160 + 160 q The work equipment pump No.1 has two variable displacement swash plate type piston pumps, and a servo valve is attached to the front pump, and the servo and CO + NC valves are attached to the rear pump.

10-139

P: Main pump pressure IN port PA1: Front pump discharge port PA2: Rear pump discharge port PD11: Drain port PD21: Drain port PES1: ES valve output pressure IN port PES2: ES valve output pressure IN port PS: Pump suction port PSV: Servo source pressure supply port

1. Front pump 2. Front servo valve 3. Rear servo valve 4. Rear CO+NC valve 5. Rear pump

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10-139

Hydraulic system Work equipment pump No.1

Work equipment pump No.1 (HPV160 + 160)

10-140

PSV1: Servo valve source pressure port PSV1A: Servo valve output port PSV1B: Servo valve output port

PSV2: Servo valve source pressure port PSV2A: Servo valve output port PSV2B: Servo valve output port

10-140

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Hydraulic system Work equipment pump No.1

1. Front shaft 2. Front cradle 3. Front case 4. Rocker cam 5. Piston 6. Cylinder block 7. Valve plate

8. Front end cap 9. Coupling 10. Impeller 11. Rear end cap 12. Valve plate 13. Cylinder block 14. Piston

15. Rocker cam 16. Rear case 17. Rear cradle 18. Rear shaft 19. Servo piston

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10-141

Hydraulic system Work equipment pump No.1

Servo valve (front)

10-142

P2: Main pump pressure IN port PAC1: Servo actuator port PAC2: Servo actuator port PDR: Servo valve drain OUT port PES1: ES valve output pressure IN port PPO: Servo source pressure IN port

1. Servo valve

10-142

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Hydraulic system Work equipment pump No.1

Servo valve, CO + NC valve Assy (rear)

10-143

P: Main pump pressure IN port PAC1: Servo actuator port PAC2: Servo actuator port PDR: Servo valve drain OUT port PECN: CO + NC valve output pressure port PES: ES valve pressure pickup port PES2: ES valve output pressure IN port PPO: Servo source pressure IN port

1. CO+NC valve 2. Servo valve 3. Plate

WA1200-6

10-143

Hydraulic system Work equipment pump No.1

1. Servo valve (rear)

10-14

P1I: Main pump pressure IN port P1O: Main pump pressure OUT port P2I: Main pump pressure IN port P2O: Main pump pressure OUT port

PDR: CO + NC valve drain port PPO: Servo source pressure OUT port PECN: CO + NC valve output pressure IN port

10-144

WA1200-6

Hydraulic system Work equipment pump No.1

Structure

10-145

1. Locknut 2. Cover 3. Plug 4. Spring 5. Valve body 6. Arm

7. Pin 8. Piston 9. Locknut 10. Plug 11. Locknut 12. Cover

13. Sleeve 14. Piston 15. Spring 16. Plug 17. Cover 18. Locknut

Function 10-145 q The deliveries Q1 and Q2 of main pumps P1 and P2 are controlled individually by respective servo 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 Work equipment pump No.1

1) Operation to increase pump delivery (angle increases)

10-146

Operation q Control pump pressure PPO is led to port a. q Signal pressure PECN from NC valve is led through port b into chamber c. q When signal pressure PECN increases, the pressure of chamber c pushes piston (8) to the right where the force of spring (4) balances. q At the same time, similar to piston (8), arm (6) oscillates rightward around servo piston (19) as a fulcrum to move guide spool (13) to the right. q As guide spool (13) moves, ports a and d are 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 At the same time, port a connects to port h and pressurized oil flows through port i into servo piston chamber j to push servo piston (19) to the right, so the swash plate angle of the main pump increases and the pump delivery also increases. As servo piston (19) moves, arm (6) turns around pin (7) in the counterclockwise direction to move guide spool (13) to the left. Then, ports a, d, and h are closed, so delivery increases according to signal pressure PECN.

10-146

WA1200-6

Hydraulic system Work equipment pump No.1

2) Operation to decrease pump delivery (angle decreases)

10-147

Operation q When signal pressure PECN decreases, piston (8) moves to the left where the force of spring (4) balances with the pressure of chamber c. q At the same time, similar to piston (8), arm (6) oscillates leftward around servo piston (19) as a fulcrum to move guide spool (13) to the left. q As guide spool (13) moves, ports a and h are closed. Furthermore, port h connects to drain chamber e. This also connects servo piston chamber j to drain chamber e via ports i and h.

10-147 At the same time, port a connects to port d and the pressurized oil flows through port g into servo piston chamber f to push servo piston (19) to the right, so the swash plate angle of the main pump decreases and the pump delivery also decreases. As servo piston (19) moves, arm (6) turns around pin (7) in the clockwise direction to move guide spool (13) to the right. Then, ports a, d, and h are closed, so the delivery decreases according to signal pressure PECN.

WA1200-6

10-147

Hydraulic system Work equipment pump No.1

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 Work equipment pump No.1

CO valve 1. Cover 2. Sleeve 3. Piston 4. Spool 5. Spring 6. Seat 7. Plug

NC valve 8. Cover 9. Sleeve 10. Piston 11. Spool 12. Spring 13. Cover

WA1200-6

10-149

Hydraulic system Work equipment pump No.1

3.CO valve Function q When a load increases and the main pump delivery pressure increases and the pressure comes close to the relief pressure during operation, the CO valve reduces the delivery and relief loss by using its cutoff function.

10-150 10-150 The CO valve is controlled by balancing the sum of main pump delivery pressure P and CO valve output pressure PEC with a spring.

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 Work equipment pump No.1

2) When main pump delivery pressure comes close to relief pressure

10-151

Operation q When a load increases and the main pump delivery pressure P comes close to the relief pressure, 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.

10-151

WA1200-6

10-151

Hydraulic system Work equipment pump No.2

Work equipment pump No.2

Model: HPV95 + 95 + SAL(2) 40 q The work equipment pump No.2 has two variable 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

10-152

WA1200-6

Hydraulic system Work equipment pump No.2

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 PES1: ES valve output pressure IN port PESO: ES valve output pressure OUT port PS: Pump suction 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

Work equipment pump No.2 (HPV95 + 95)

10-154

PSV1: Servo valve source pressure port PSV1A: Servo valve output port PSV1B: Servo valve output port

PSV2: Servo valve source pressure port PSV2A: Servo valve output port PSV2B: Servo valve output port

10-154

WA1200-6

Hydraulic system Work equipment pump No.2

1. Front shaft 2. Front cradle 3. Front case 4. Rocker cam 5. Piston 6. Cylinder block 7. Valve plate

8. Front end cap 9. Coupling 10. Impeller 11. Rear end cap 12. Valve plate 13. Cylinder block 14. Piston

15. Rear case 16. Rocker cam 17. Rear cradle 18. Rear shaft 19. Servo piston

WA1200-6

10-155

Hydraulic system Work equipment pump No.2

Servo valve, CO + NC valve Assy (front side)

10-156

P: Main pump pressure IN port P2: Main pump pressure IN port PAC1: Servo actuator port PAC2: Servo actuator port PDR: Servo valve drain OUT port PECN: CO + NC valve output pressure OUT port PES: ES valve output port PPO: Servo source pressure IN port

1. CO + NC valve 2. Servo valve 3. Plate

10-156

WA1200-6

Hydraulic system Work equipment pump No.2

1. Servo valve (front)

10-157

P2: Main pump pressure OUT port PDR: CO + NC valve drain IN port PECN: CO + NC valve output pressure IN port

For information on the structure, function, and operation, refer to the section "1. servo valve (rear)".

WA1200-6

10-157

Hydraulic system Work equipment pump No.2

2. CO + NC valve (front)

10-158

P: Main pump pressure IN port PDR: CO + NC valve drain OUT port PECN: CO + NC valve output pressure OUT port

10-158

WA1200-6

Hydraulic system Work equipment pump No.2

CO valve 1. Cover 2. Sleeve 3. Piston 4. Spool 5. Spring 6. Seat 7. Plug

NC valve 8. Cover 9. Sleeve 10. Piston 11. Spool 12. Spring 13. Cover

WA1200-6

10-159

Hydraulic system Work equipment pump No.2

CO valve Function q When a load increases and the main pump delivery pressure increases and the pressure comes close to the relief pressure during operation, the CO valve reduces the delivery and relief loss by using its cutoff function.

10-160 10-160 The CO valve is controlled by balancing the sum of main pump delivery pressure P and CO valve output pressure PEC with a spring.

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 output pressure PEC maximum and the main pump delivery becomes maximum.

10-160

WA1200-6

Hydraulic system Work equipment pump No.2

2) When main pump delivery pressure comes close to relief pressure

10-161

Operation q When a load increases and the main pump delivery pressure P comes close to the relief pressure, 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.

10-161

WA1200-6

10-161

Hydraulic system Work equipment pump No.2

Servo valve, TVC valve, ES valve Assy (rear)

10-162

P1: Main pump pressure IN port P2: Main pump pressure IN port PAC1: Servo actuator port PAC2: Servo actuator port PDR: Servo valve drain OUT port PES: ES valve output pressure OUT port PECN: CO + NC valve output IN port P1N1: Main pump pressure IN port P1N2: Main pump pressure IN port

PPO: Servo source pressure IN port POR1: Orifice upstream pressure IN port POR2: Orifice downstream pressure IN port 1. ES valve 2. Block 3. TVC valve 4. Servo valve 5. Connector

10-162

WA1200-6

Hydraulic system Work equipment pump No.2

1. Servo valve (rear)

10-163

P1: Main pump pressure OUT port P2: Main pump pressure OUT port PDR: ES valve drain IN port

PPO: Servo source pressure OUT port PECN: CO + NC valve output pressure IN port

WA1200-6

10-163

Hydraulic system Work equipment pump No.2

Structure

10-164

1. Locknut 2. Cover 3. Plug 4. Spring 5. Valve body 6. Arm

7. Pin 8. Piston 9. Locknut 10. Plug 11. Locknut 12. Cover

13. Sleeve 14. Piston 15. Spring 16. Plug 17. Cover 18. Locknut

Function 10-164 q The deliveries Q1 and Q2 of main pumps P1 and P2 are controlled individually by respective servo 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 Work equipment pump No.2

1) Operation to increase pump delivery (angle increases)

10-165

Operation q Signal pressure PI acts via port D on chamber E in the control piston part. Also, control pump pressure PC is led to port B. q When PI increases, the oil pressure acting on chamber E increases and control piston (9) moves to the right until the force of spring (10) balances with the oil pressure of chamber E. q At the same time, arm (4) oscillates rightward around servo piston (11) as a fulcrum to move guide spool (12) to the right.

10-165 As guide spool (12) moves, ports B and A connect to each other, control pump pressure PC flows into chamber F in servo piston (11) to push servo piston (11) to the right. So, the swash plate angle of the main pump increases to increase the delivery. This makes arm (4) turn around pin (13) in the counterclockwise direction to move guide spool (12) to the left. Then, ports B, A, and C are closed, so delivery increases according to signal pressure PI.

WA1200-6

10-165

Hydraulic system Work equipment pump No.2

2) Operation to decrease pump delivery (angle decreases)

10-16

Operation q When signal pressure PI decreases, piston (9) moves to the left where the force of spring (10) balances with the pressure of chamber E. q At the same time, similar to piston (9), arm (4) oscillates leftward around servo piston (11) as a fulcrum to move guide spool (12) to the left. q As guide spool (12) moves, ports B and A are closed. Furthermore, port A connects to drain chamber T. This also connects servo piston chamber F to drain chamber T via port A.

10-16 At the same time, port B connects to port C and the pressurized oil flows into servo piston chamber H to push servo piston (11) to the left along with the force of spring (14), so the swash plate angle of the main pump decreases and the pump delivery also decreases. As servo piston (11) moves, arm (4) turns around pin (13) in the clockwise direction to move guide spool (12) to the right. Then, ports B, C, and A are closed, so delivery decreases according to signal pressure PI.

10-166

WA1200-6

Hydraulic system Work equipment pump No.2

2. TVC valve (rear)

10-167

PPO: Servo source pressure IN port P1: Main pump pressure IN port P2: Main pump pressure IN port PDR: TVC valve drain OUT port PE: TVC valve output pressure OUT port

1. Spring 2. Spool 3. Piston 4. Piston

5. Sleeve 6. Piston 7. Body 8. Solenoid

WA1200-6

10-167

Hydraulic system Work equipment pump No.2

Function The command current from the controller according to the engine speed makes the pump delivery optimal.

1) When command current from controller is small

10-168 When the emergency pump drive switch is turned ON, the pump delivery is controlled according to the pump delivery pressure (load) by the hydraulic sensing based on a certain pump absorption torque. 10-168

Operation q The command current sent from the controller moves solenoid push pin (9) to move spool (2). Spool (2) stops in the position where spring (1), push pin (9), and TVC valve output pressure PTVC balance with the force acting on piston (3). Here, the command current is small and the force of push pin (9) is small, so spool (2) balances at lower part.

10-168 In consequence, ports a and b are almost fully open and almost all pressurized oil from the control pump is output as the TVC valve output pressure PTVC. TVC valve output pressure PTVC increases and signal pressure PECN increases, so the pump delivery increases.

10-168

WA1200-6

Hydraulic system Work equipment pump No.2

2) When command current from controller is large

10-169

Operation q The command current sent from the controller moves solenoid push pin (9) to move spool (2). Spool (2) stops in the position where spool (2) balances with spring (1). Here, the command current is large and the force of push pin (9) is large, so spool (2) balances at upper part.

10-169 As a result, the flow from port a to port b is throttled to increase the opening areas of ports b and c (drain port). Thus, TVC valve output pressure PE decreases and signal pressure PECN decreases, so the pump delivery decreases.

WA1200-6

10-169

Hydraulic system Work equipment pump No.2

3) When the emergency pump drive switch is turned ON and pump load is small

10-170

Operation 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 increases and the pump delivery increases.

10-170

10-170

WA1200-6

Hydraulic system Work equipment pump No.2

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) upward. 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 decreases and the pump delivery decreases.

WA1200-6

10-171

Hydraulic system Work equipment pump No.2

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 PPO: Servo source pressure IN port

10-172

WA1200-6

Hydraulic system Work equipment pump No.2

1. Cover 2. Plug 3. Rod 4. Plug 5. Nut 6. Screw

7. Cover 8. Sleeve 9. Piston 10. Spool 11. Cover

WA1200-6

10-173

Hydraulic system Work equipment pump No.2

Function The valve controls the delivery rate of the work equipment pump according to the change of engine speed. q The work equipment pump employs the variable capacity type piston pump in order to reduce the oil pressure consumption in the low-speed range of the engine for attaining an energy saving, and at the same time, to improve the engine acceleration performance from low-speed. q Therefore, the delivery (delivery per rotation) is changed based on the engine speed by converting the engine speed into differential pressure by using the differential pressure valve.
q

10-174 Until the pilot pressure reaches to the differential pressure 0.37 MPa {3.8 kg/cm2}, the pump delivery (delivery per rotation) increases in proportion to the increase of the differential pilot pressure, that is, in proportion to the increase of engine speed. When the differential pressure reaches 0.37 MPa {3.8 kg/cm2}, the pump delivery (delivery per rotation) becomes maximum. When differential pilot pressure is at point a or smaller

When differential pilot pressure is at point b or larger 10-174 Operation The oil from the PPC pump is sent through differential 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 increases as the flow rate from PPC pump increases, 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 cylinder. q As the swash plate angle changes, the piston stroke of the pump changes and the pump delivery (delivery per rotation when the differential pilot pressure is at point b) changes.
q

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 10-176 Function When the work equipment lever is operated, the EPC valve supplies the hydraulic pilot pressure to the work equipment valve by using the proportional 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)

10-178 Outline The neutral cutoff solenoid valve (NC valve) is installed between the differential valve and ES valve of work equipment pump No.2 to change the delivery of work equipment pumps No.1 and No.2 according 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 consumption by reducing the pump flow rate supplied 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 10-178 Operation 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 pressure 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 3. Pilot poppet 4. Spring 5. Adjustment screw Set pressure: For PPC: 2.9 MPa {30 kg/cm2} For pump control: 2.9 MPa {30 kg/cm2} 10-179 Function 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 The relief valve for pump control is installed between the pump for controlling main pump and the main pump. This relief valve relieves the oil sent from the control pump to maintain the pressure main pump control circuit at the constant level. 10-179 Operation Port A is connected to the pump circuit, and port C to the drain circuit. The oil goes through the orifice in main valve (1) and port B is filled with the oil. And, pilot poppet (3) keeps in touch with valve seat (2).

When the pressures in ports A and B reach the set pressure of poppet spring, pilot poppet (3) opens and the oil pressure in port B is released through port D to port C to reduce the pressure in port B.

When the pressure in port B decreases, the orifice in main valve (1) causes differential pressure between ports A and B and the pressure of port A opens main valve (1) to release the oil in port A.

WA1200-6

10-179

Hydraulic system Accumulator (for EPC valve)

Accumulator (for EPC valve)

10-180
10-180 Operation q When the work equipment valve is in neutral after the engine stops, chamber A in bladder (4) (amount of nitrogen gas: 3,000 cc) is compressed by chamber B. q When EPC valve is operated, the hydraulic pressure in chamber B becomes 2.9 MPa {30 kg/cm2} or lower and the nitrogen gas pressure in chamber A expands bladder (4). Therefore, the oil flows into EPC valve to activate EPC valve and move the work equipment valve. a Operating pressure: 1.6 to 2.9 MPa {16 to 30 kg/cm2}

1. Cap 2. Nut 3. Body

4. Bladder 5. Oil port 6. Nut

Specifications q Type of gas: nitrogen gas (N2) q Volume of gas: 3,000 cc q Maximum operating pressure: {30 kg/cm2} q Minimum operating pressure: 2} {16 kg/cm

10-180

2.9 1.6

MPa MPa

10-180 Function 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 2. Bucket spool return spring 3. Lift arm spool return spring 4. Lift arm spool 5. Bucket spool 6. Body 7. Suction safety valve 8. Unload valve 9. Float selector valve

PA1: From C1 of EPC valve PA2: From C3 of EPC valve PB1: From C2 of EPC valve PB2: From C4 of EPC valve A1: To bucket cylinder bottom A2: To lift arm cylinder bottom B1: To bucket cylinder rod side B2: To lift arm cylinder rod side P: Pump port PI: From C4 of EPC valve T: Drain port

WA1200-6

10-181

Hydraulic system Work equipment control valve

Outline Three work equipment control valves are installed because the pump flow rate is large. This controls the operation of bucket and attachment in the hydraulic system and its circuit is a tandem circuit where a priority is given to the bucket circuit. The work equipment control valve activates 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.
q

10-182 In order to protect the circuit from unusual pressure, two safety valves (with suction) (7) are installed to the bucket circuit. Note that, of two safety valves, the one works as a relief valve and the other refills the oil shortage as a suction valve.

10-182

WA1200-6

Hydraulic system Work equipment control valve

Main relief valve

10-183

1. Valve 2. Piston 3. Piston spring 4. Poppet 5. Poppet spring 6. Plug with valve seat 7. Sleeve 8. Adjustment screw 9. Locknut Set pressure: 31.9 MPa {325 kg/cm2} 10-183 Function 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 maximum pressure of the work equipment circuit and protect the circuit. 10-183 Operation Port (A) is connected to the pump circuit and port (B) is connected to the drain circuit. The pressurized oil in port (A) is led through hole (b) in piston (2) to port (C). q When the pressurized oil in port (A) is not more than the relief set pressure, poppet (4) comes into contact with the seat in plug (6) to shut off the flow from chamber (C) to the drain circuit, so the pressures of oil in port (A) is equal to pressures 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
q

When the pump pressure reaches the relief pressure set by spring (5), poppet (4) opens, and the pressurized oil in chamber (C) is drained into chamber (D). As poppet (4) opens, the flow occurs as (A)o(C)o(D).

As the pressure drops in the flow of (A) to (C) through hollow hole (b) in piston (2), the pressure of chamber (C) drops against port (A), and valve (1) moves to the right. And, the pressurized oil flows from port (A) to port (B) to control the maximum oil pressure and protect the circuit.

WA1200-6

10-183

Hydraulic system Work equipment control valve

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 pressurized 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 10. Locknut Set pressure: 33.8 MPa {345 kg/cm2} 10-184 Function q When unusual pressure occurs due to some impact on the cylinder, the unusual pressure is released 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.

When unusual pressure occurs in port A to reach the set pressure of spring (6), poppet (5) opens and the oil in chamber C is drained through chamber D and circumference a of suction valve (1).

10-184

WA1200-6

Hydraulic system Work equipment control valve

As poppet (5) opens, the pressure drops in chamber C, and piston (3) moves rightward. Piston (3) comes into contact with the end of poppet (4), and the oil is drained through throttle b into chamber D.

Operation as a suction valve: q When the negative pressure occurs in the cylinder circuit, port A is interconnected to chamber C, so both pressures becomes negative.Port E is receiving tank pressure of port B, and the pressure of suction valve (1) increases in proportion to the area difference between d5 and d1 due to tank pressure of E.This increased pressure compresses spring (7) to move suction valve (1) to rightward.Thus, oil flows from port B to port A to prevent occurring of negative pressure at port A.

As the pressure in chamber C is lower than the pressure in port A, main valve (2) moves rightward and the oil flows from port A into port B to prevent the occurrence of unusual pressure. Even if unusual pressure occurs, as the diameter 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 Work equipment control valve

Float selector valve and unload valve Function 10-186 q There are float selector valve (2) and unload valve (3) in the work equipment valve. When the lift arm lever is put in the float position, float selector valve (2) detects it and starts to activate unload valve (3) to put the lift arm in the float position. 10-186 Operation 1. Lower position 10-186 q The lift arm lever in the lower position is shown.

10-186 10-186 2. Float position q As the lift arm lever in lower position is pushed further the lever is put it in float position. The position of lift arm spool (1) in the work equipment valve is the same as the lower position. Since the oil pressure of port (A) becomes higher than that of LOWER port, float selector valve (2) moves rightward, then back pressure of unload valve (3) is drained.Accordingly, unload valve (3) opens and the lift arm becomes FLOAT state.

10-186

WA1200-6

Hydraulic system Work equipment control valve

3. Float position (ride over) 10-187 q If the machine rolls back and the lift arm rises, cylinder rod side becomes high pressure, then oil flows through port (B) and drains through unload valve (3).Cylinder bottom side becomes vacuum and oil flows in through port (C).

10-187 4. Float position (hydraulic drift) q If the machine rolls back and the lift arm drops by its own weight, cylinder bottom side becomes high pressure, then oil drains through port (C).Cylinder rod side becomes vacuum and oil flows in through port (B).

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Hydraulic system Work equipment control valve

Operation in hydraulic circuit Lift arm and bucket spool in neutral position

10-18 10-18

Operation q The oil enters through the steering valve into port (A) and relief valve (11) regulates maximum oil pressure. q As bucket spool (1) is in neutral, the bypass circuit opens, the oil in port (A) flows through surrounding 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 surrounding area of the spool into port (C) in the drain circuit and returns through filter in the hydraulic tank.

10-18 The oil from the PPC pump enters through check valve (13) into port (L) in EPC valve. But, as the lift arm and bucket lever are in neutral position, the oil returns from PPC relief valve (12) into hydraulic tank.

10-188

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Hydraulic system Work equipment control valve

Lift arm spool in raise position

10-189

Operation q When lift arm lever (3) is pulled, the oil flows from port (L) in EPC valve to ports (N) and (T). Also, the oil in port (S) flows through port (M) into the drain circuit. The pressurized oil in port (T) pushes lift arm spool (2) to put it in raise position. q The oil from 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 (H) and (I) into the cylinder bottom.

10-189 On the other hand, the oil in the cylinder head returns from port (K) through drain port (C) to the tank. Consequently, the lift arm rises.

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Hydraulic system Work equipment control valve

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

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Hydraulic system Work equipment control valve

Lift arm spool in float position

10-191

Operation q When lift arm lever (3) is pushed into the float position, the pressurized oil in port (L) of the EPC valve flows into port (M) and ports (S) and (W) as well. Also, the oil in port (T) flows into port (N). q The pressurized oil in port (S) pushes down lift 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 connected to the drain circuit, unload valve (8) moves up to flow the oil from the pump into the drain circuit.

10-191 Consequently, the oil in the cylinder head flows through port (K) and unload valve (8) into the drain circuit. The oil in the cylinder bottom flows through ports (I) and (C) into the drain circuit. Hence, the lift arm is put in float condition.

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Hydraulic system Work equipment control valve

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

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Hydraulic system Work equipment control valve

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 bottom. q On the other hand, the oil in the cylinder head returns from port (G) through drain port (C) to the tank. Consequently, the bucket tilts.

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10-193

Work equipment Work equipment linkage

Work equipment

Work equipment linkage

10-194

10-194

1. Bucket 2. Bucket link 3. Bell crank 4. Bucket cylinder

5. Lift arm 6. Lift arm cylinder 7. Tip tooth 8. Sweeper wing

10-194

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Work equipment Work equipment linkage

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)

10-195 Outline All linkage pins of the work equipment employ the oil sealed type.

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10-195

Electrical system Machine monitor system

Electrical system

Machine monitor system

Outline q In the machine monitor system, controllers connected to the network monitor the machine condition 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

10-196
10-196

10-196

The machine monitor has two display modes; the normal mode and service mode. 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, hydraulic 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 displayed on character display 2. Initializing function Use this function to return the settings of the machine monitor to the factory default.

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Electrical system Machine monitor system

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10-197

Electrical system Machine monitor system

Machine monitor electric circuit diagram

10-198

10-198

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Electrical system Machine monitor system

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10-199

Electrical system Machine monitor system

Machine monitor

10-20

1. Auto/manual shift selection pilot lamp 2. Shift lever position pilot lamp (gear speed) 3. Shift lever position pilot lamp (travel direction) 4. Torque converter oil temperature gauge 5. Torque converter oil temperature caution lamp 6. Engine coolant temperature gauge 7. Engine coolant temperature caution lamp 8. Tachometer 8A. Travel speed or engine speed 8B. Display unit for travel speed or engine speed 8C. Payload measured by load meter 8D. Type of material set in load meter 8E. Payload or target payload 8F. Designation of payload or target payload 9. Turn signal pilot lamp (left) 10. Turn signal pilot lamp (right) 11. Hydraulic oil temperature caution lamp 12. Hydraulic oil temperature gauge 13. Fuel level caution lamp 14. Fuel gauge 15. Centralized warning lamp

16. Brake oil pressure caution lamp 17. Engine oil pressure caution lamp 18. Hydraulic oil level caution lamp 19. Engine oil level caution lamp 20. Engine coolant level caution lamp 21. Transmission filter clogging caution lamp 22. Air cleaner clogging caution lamp 23. Parking brake pilot lamp 24. Brake oil temperature caution lamp 25. WIF separator caution lamp 26. Pre-lubrication pilot lamp 27. Maintenance monitor 28. Battery electrolyte level caution lamp 29. Battery charge level caution lamp 30. Emergency steering "Inactive" pilot lamp 31. Emergency steering at "Operation" pilot lamp 32. Character display 33. Auto-excavation pilot lamp 34. Auto-greasing pilot lamp 35. AJSS pilot lamp 36. Economy operation indicator 37. Gear shift indicator

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Electrical system Machine monitor system

1. Traction control dial 2. Travel speed control dial 3. Travel speed LED 4. Active working switch 5. Emergency flashing lamp switch 6. Headlamp switch 7. Service meter display switch

8. Main monitor illuminance control switch (LED/LCD selection) 9. Main monitor illuminance control switch (illuminance increase or decrease) 10. Load meter switch 11. Parking brake switch 12. Starting switch

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Electrical system Machine monitor 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. (*) indiLED color cated in (when light"Machin ing up) e monitor" Night lighting dimming Enabled: q Disabled: Operation during self-check (at key ON) Signal input circuit: Direct signal Display condition or operation specifiinput or through cation CAN q 1 Tachometer 8 q Back light color: White For 2 seconds: Fully lights up. For 1 second: Fully goes out. Upper: KOMATS Lower: No display Displayed at the center for 3 seconds. CAN (transmission controller) q Uses all 4 digits for engine speed display, but 0 (zero) is always displayed in unit's place. Numeral value in unit's place of engine speed is rounded to nearest whole number.

No.

Item

Remarks

Character display (Upper: Service meter) (Lower: Speed meter) Engine coolant temperature gauge

32

LCD Character: Black Background: Gray

q Back light

CAN (transmission controller) q q CAN (transmission controller q [Engine controlq ler]) q q Lower limit: 50 C Needle at horizontal position: 85 C Red zone start point: 102 C Upper limit: 135 C (Scale marks are spaced uniformly.) Lower limit: 50 C Needle at horizontal position: 110 C Red zone start point: 120 C Upper limit: 135 C (Scale marks are spaced uniformly.) Lower limit: 0 % Upper limit: 100 % (Scale marks are spaced uniformly.) (Caution lamp lights up when fuel level is lower than start point.) Lower limit: 50 C Needle at horizontal position: 85 C Red zone start point: 105 C Upper limit: 125 C (Scale marks are spaced uniformly.) Lights up or goes out according to command from transmission controller. Lights up or goes out according to command from transmission controller. Actual gear speed is displayed according to command from transmission controller. Lights up or goes out according to command from transmission controller. Normally goes out except during self-check if this function is disabled in option setting. Detection condition: CNFC04 (pin 3) is OPEN and travel speed is 1 km/h or faster. Detection time: 1 second Reset condition: CNFC04 (pin 3) is CLOSE. Reset time: 1 second Lights up or goes out according to command from transmission controller. CNFC02 (pin 3) is OPEN: Flashes. CNFC02 (pin 3) is CLOSE: Lights up.

q Back light

Needle stays at stop position (fixed).

Torque converter oil temperature gauge

q Back light

Needle stays at stop position (fixed).

Monitor panel (sensor input)

q q q q

Fuel gauge

14

q Back light

Needle stays at stop position (fixed).

Monitor panel (sensor input)

Hydraulic oil temperature gauge

12

q Back light

Needle stays at stop position (fixed).

q q Monitor panel (sensor input) q q

Shift lever position pilot lamp (travel direction) Shift lever position pilot lamp (gear speed) Gear shift indicator

F: Green N: Orange R: Green

For 2 seconds: Fully lights up. For 1 second: Fully goes out. For 2 seconds: Fully lights up. For 1 second: Fully goes out. For 2 seconds: Fully lights up. For 1 second: Fully goes out. For 2 seconds: Fully lights up. For 1 second: Fully goes out.

CAN (transmission controller) q Signal filtering is performed by monitor panel. CAN (transmission controller) CAN (transmission controller) q

Green

q q Back light color: White

37

q CAN (transmission controller) q q

10

Economy operation indicator

36

Green

Emergency 11 steering "Inactive" pilot lamp

30

Green

For 2 seconds: Fully lights up. For 1 second: Fully goes out. For 2 seconds: Fully lights up. For 1 second: Fully goes out. For 2 seconds: Fully lights up. For 1 second: Fully goes out.

Monitor panel

q q q

Auto/manual 12 shift selection pilot lamp 13 Auto-greasing pilot lamp

Green

CAN (transmission controller)

q Monitor panel q

34

Green

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Electrical system Machine monitor system

(*): The numbers indicated here correspond to the numbers shown in "Machine monitor". Be sure to check their positions and symbols. Item No. (*) indiLED color cated in (when light"Machin ing up) e monitor" Night lighting dimming Enabled: q Disabled: Operation during self-check (at key ON) Signal input circuit: Direct signal Display condition or operation specifiinput or through cation CAN q Lights up, goes out, /flashes (interconnected buzzer (B) sounds), or flashes (buzzer does not sound) according to command from transmission controller. Work equipment controller commands to flash (via transmission controller). Flashing has 2 patterns; accompanied with or without sounding buzzer. Priority is as follows. Flashing with buzzer sounding > flashing > lighting up > going out Lights up or goes out according to commands from work equipment controller. Operates according to input signal (CN-FC02 (pin 2): Starting motor terminal C). OPEN: Goes out CLOSE: Lights up Obtains information on maintenance items from VHMS at key ON, whose remaining time to maintenance is; Remaining time to maintenance Z 0 hour 0 hour < remaining time to maintenance Z 30 hours Lighting condition: Lights up for 30 seconds after self-check and then goes out if any item meets above condition 1. 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. Flashes according to input signal. OPEN: Goes out CLOSE: Lights up

No.

Item

Remarks

14 AJSS pilot lamp

35

Green

For 2 seconds: CAN (work equipq Fully lights up. ment controller) For 1 second: Fully CAN (transmisgoes out. sion controller) q q For 2 seconds: q Fully lights up. CAN (work equipFor 1 second: Fully ment controller) goes out. q For 2 seconds: Fully lights up. Monitor panel For 1 second: Fully q goes out. q q

15

Auto-excavation pilot lamp

33

Green

Pre-lubrication 16 pilot lamp

26

Orange

1. 2. For 2 seconds: Fully lights up. CAN q For 1 second: Fully (KOMTRAX Plus) goes out. q

Maintenance 17 monitor

27

Red

Turn signal pilot 18 lamp (left and right)

9, 10

Green

For 2 seconds: Fully lights up. For 1 second: Fully goes out.

q Monitor panel q q

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Electrical system Machine monitor system

(*): The numbers indicated here correspond to the numbers shown in "Machine monitor". Be sure to check their positions and symbols. Item No. (*) indiLED color cated in (when light"Machin ing up) e monitor" Red Night lighting dimming Enabled: q Disabled: Operation during self-check (at key ON) For 2 seconds: Fully lights up. For 1 second: Fully goes out. Signal input circuit: Direct signal Display condition or operation specifiinput or through cation CAN Monitor panel q CAN (each controller) Lights up or goes out according to command from each controller.

No.

Item

Remarks

19

Centralized warning lamp

15

20

Emergency steering "Active" pilot lamp

31

Red

Battery charge 21 level caution lamp

29

Red

Battery electro22 lyte level caution lamp

28

Red

(Special 1) q Detection condition: Engine running 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 running judgment is ON, parking brake is ON (OPEN) and shift lever is in a position other than N. q Detection time: Immediate q Reset condition: Release from detection condition q Reset time: Immediate q Operation: Centralized warning lamp lights up and buzzer 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). q Reset time: Immediate q Operation: Centralized warning lamp lights up and buzzer sounds (A). Detection condition: CNFC04 (pin 3) For 2 seconds: is OPEN. Fully lights up. Detection time: Immediate Monitor panel For 1 second: Fully Reset condition: CNFC04 (pin 3) is 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 input, and engine running judgment is ON. q Detection time: 30 seconds q Reset condition: 12 V or more q Reset time: 1 second q Operation: this caution lamp lights up, centralized warning lamp lights up, buzzer sounds (A), and failure code (AB00MA) For 2 seconds: Monitor panel is displayed and recorded. Fully lights up. (sensor input) 2. When failure in charging circuit For 1 second: Fully CAN (KOMTRAX occurs goes out. Plus) q Detection condition: Alternator voltage is 12 V or higher when engine is stopped. q Detection time: 3 seconds q Reset condition: 5 V or less when engine is stopped q Reset time: 1 second q Operation: this caution lamp lights up, and failure code (AB00L6) is displayed and recorded. 3. When VHMS error (AB00MB) occurs For 2 seconds: Fully lights up. CAN q Lights up or goes out according For 1 second: Fully (KOMTRAX Plus) to commands from VHMS. goes out.

Alternator voltage (see the drawing.)

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Electrical system Machine monitor system

(*): The numbers indicated here correspond to the numbers shown in "Machine monitor". Be sure to check their positions and symbols. Item No. (*) indiLED color cated in (when light"Machin ing up) e monitor" 23 Red Night lighting dimming Enabled: q Disabled: Operation during self-check (at key ON) For 2 seconds: Fully lights up. For 1 second: Fully goes out. Signal input circuit: Direct signal Display condition or operation specifiinput or through cation CAN q Monitor panel Lights up or goes out according to input signal. q OPEN: Lights up. q CLOSE: Goes out. (Notice warning) q Detection (reset) condition: 120 C or more (less) q Detection time: 5 seconds 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 Detection time: 5 seconds q Reset condition: Less than 125 C q Reset time: 5 seconds q Operation: This caution lamp lights up, centralized warning lamp lights up, buzzer sounds (A), and failure code (B@C6NS) is displayed and recorded. (2) q Detection condition: 125 C or more q Detection time: 5 seconds q Regular alarm is raised if travel speed is 35 km/h or more after the above conditions are satisfied (including the moment of satisfaction). q Reset condition: Less than 125 C q Reset time: 5 seconds q Operation: This caution lamp lights up, centralized warning lamp lights up, buzzer sounds (A), and failure code (B@C6NS) is displayed and recorded.

No.

Item

Remarks

23

Parking brake pilot lamp

Brake oil tem24 perature caution lamp

24

Red

For 2 seconds: Fully lights up. For 1 second: Fully goes out.

Monitor panel (sensor input)

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Electrical system Machine monitor system

(*): The numbers indicated here correspond to the numbers shown in "Machine monitor". Be sure to check their positions and symbols. Item No. (*) indiLED color cated in (when light"Machin ing up) e monitor" Night lighting dimming Enabled: q Disabled: Operation during self-check (at key ON) Signal input circuit: Direct signal Display condition or operation specifiinput or through cation CAN Condition (1): At key ON q Detection condition: Brake oil pressure drops (transmission controller communication data). q Detection time: 1 second q Reset condition: Brake oil pressure returns to normal (transmission controller communication data). q Reset time: 1 second q Operation: This caution lamp lights up. Condition (2): Within 60 seconds after engine running judgment ON after key ON q Detection condition: Brake oil pressure drops (transmission controller communication data). q Detection time: 1 second q Reset condition: Brake oil pressure returns to normal (transmission controller communication CAN (transmisdata). sion controller) Reset time: 1 second Judgment on the q Operation: This caution lamp monitor panel lights up, centralized warning lamp lights up and buzzer sounds (A). Condition (3): 60 seconds or later after engine running judgment becomes ON q Detection condition: Brake oil pressure drops (transmission controller communication data). q q Detection time: 5 seconds Reset condition: Brake oil pressure returns to normal (transmission controller communication data). Reset time: 1 second Operation: This caution lamp lights up, centralized warning lamp lights up, buzzer sounds (A), and failure code ([F]2G42ZG or [R] 2G43ZG) is displayed and recorded. Lights up or goes out according to command from engine controller. Lights up when engine controller generates failure code CA415. Lights up or goes out according to command from engine controller. Lights up when engine controller generates failure code CA1544. Detection condition: SW (OPEN) Detection time: 30 seconds Reset condition: SW (CLOSE) Reset time: 1 second Operation: This caution lamp lights up, and failure code (B@BCZK) is displayed and recorded.

No.

Item

Remarks

Brake oil pressure caution lamp 25 (F and R brake oil pressure are sensed separately.)

16

Red

For 2 seconds: Fully lights up. For 1 second: Fully goes out.

q q

Engine oil pres26 sure caution lamp

17

Red

For 2 seconds: Fully lights up. For 1 second: Fully goes out. For 2 seconds: Fully lights up. For 1 second: Fully goes out.

q CAN (VHMS [ENG controller]) q q CAN (VHMS [ENG controller]) q q q q q q

Engine oil level 27 caution lamp

19

Red

Engine coolant 28 temperature caution lamp

20

Red

For 2 seconds: Fully lights up. For 1 second: Fully goes out.

Monitor panel (sensor input)

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Electrical system Machine monitor system

(*): The numbers indicated here correspond to the numbers shown in "Machine monitor". Be sure to check their positions and symbols. Item No. (*) indiLED color cated in (when light"Machin ing up) e monitor" Night lighting dimming Enabled: q Disabled: Operation during self-check (at key ON) Signal input circuit: Direct signal Display condition or operation specifiinput or through cation CAN q q q Air cleaner 29 clogging caution lamp 22 Red q For 2 seconds: Fully lights up. For 1 second: Fully goes out. Monitor panel (sensor input) q q Detection condition: Engine running judgment is ON and monitor input is OPEN. Detection time: 2 seconds Reset condition: Monitor input is GND. Reset time: 1 second Operation: This caution lamp lights up, and failure code (*) is displayed and recorded.

No.

Item

Remarks

(*) 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 Detection time: 3 seconds q Reset condition: Key at OFF position q Operation: Failure code (DHT2L6) is displayed and recorded. Transmission 30 filter clogging caution lamp For 2 seconds: Fully lights up. For 1 second: Fully goes out. Monitor panel (sensor input) (Clogging detection) q Detection condition: Engine running judgment is ON, Din_24 is OPEN or Din_34 is OPEN, torque converter oil temperature is 50 C or higher and above failure is not detected. q Detection time: 2 seconds q Reset condition: Din_24 is CLOSE and Din_34 is CLOSE. q Reset time: 1 second q Operation: This caution lamp lights up, and failure code (15B0NX) is displayed and recorded. q Detection condition: SW (OPEN) q Detection time: 10 seconds q Reset condition: SW (CLOSE) q Reset time: 1 second q Operation: This caution lamp lights up and failure code (B@HAZK) is displayed and recorded. q Lights up or goes out according to command from engine controller.

21

Red

Hydraulic oil 31 level caution lamp

18

Red

For 2 seconds: Fully lights up. For 1 second: Fully goes out. For 2 seconds: Fully lights up. For 1 second: Fully goes out.

Monitor panel

32

WIF separator caution lamp

25

Red

CAN (transmission controller [Engine controller])

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Electrical system Machine monitor system

10-208 Character display function 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.

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Electrical system Machine monitor 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 communication requests caused by consecutive switch operations.) 6) Display of switch mark U and t on the character display.

7) Mode switch operations are not accepted while the self-check is performed.

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Electrical system Machine monitor system

10-210 Open-to-operator functions Self-check (0th layer) The self-check is performed for 3 seconds after the starting switch is turned to ON position (key ON). The self-check function starts automatically after key ON. After the self-check is finished (after 3 seconds), the character display automatically move to the 1st hierarchy. No mode switch operation is accepted during the self-check.

(*1): Service meter q The service meter is indicated in a number with six digits maximum including the number of decimal places. q The upper digits remains blank before carry. q The display positions of each digit of numerical value and unit are fixed as shown in the display example. (*2): Travel speed q The unit of travel speed to be displayed is that specified using the option setting function of the multi monitor.

Standard screen (1st layer) The screen changes to the following screen display automatically the after self-check.

10-210

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Electrical system Machine monitor system

Load meter function 10-21 1. Display and storage of load meter calculation data

1) The data is displayed on the above dedicated LCD. If "Non-display" is selected for the load meter display by using the multi-monitor setting function, nothing is displayed on the load meter related display area. q At addition mode setting = TOTAL LOADED lights up. At subtraction mode setting = REMAINING TARGET lights up. For materials, any one of A to E which are assigned to type of material in advance lights up. For selection of materials and modes, see "Character display load meter". q Weight display: The indications of TOTAL LOADED and TARGET LOADED display areas are as follows.
Actual weight Below -9999 -9999-1 099999 Above 99999 Display Displayed in integer number -**** Displayed in integer number ***** Displayed in integer number 99999 Displayed in integer number -9999

2) The calculated weight (payload) is indicated above the bucket illustration to the right. 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 or finish of the display holding time. q Display unit: ton (SI unit) : To change the unit to short ton, select ST (short ton) in the unit setting screen (available only when ENGLISH is selected for language). q Flashing of display: The weight display blinks (at 2 Hz) if the equality W = W1 holds for the calculation of weight W. q Display unit selection and details of data conversion for display output: All the internal data is based on SI unit (MT: metric ton) and the internal data is converted into the value expressed in the selected unit for the indication on the LCD. When On-load calibration is performed, a value expressed in the selected unit (if Short ton is selected) is input, and then the value is converted into the value expressed in Metric ton to rewrite the data. The data displayed in the real time monitor is expressed only in SI units. q Number of display digits: Integer (0 to 999) q For the weight calculation, following calculation formula is additionally applied to correct the value obtained from the average lift arm cylinder differential pressure that are measured every one second.

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Electrical system Machine monitor system

press_dt = (press_dt ) + (BA x + ENG x + HYD x + BS x + PH x + ) press_dt = Lift arm cylinder bottom-head differential pressure BA = Lift arm angle = ang_ avr (average lift arm angle) ENG = Engine speed = eng_speed HYD = Hydraulic oil temperature = hyd_temp BS = Lift arm angular velocity = boom_ang-ang_avr PH = Lift arm cylinder head pressure = ph = Correction factor for lift arm angle = Correction factor for engine speed = Correction factor for hydraulic oil temperature = Correction factor for lift arm angular velocity = Correction factor for lift arm cylinder head pressure = Intercept : Unit [MPa/ deg.] : Unit [MPa/rpm] : Unit [MPa/ C] : Unit [MPa/ deg.] : Unit [MPa/MPa] : Unit [MPa] Values are subject to the data sheet. : Unit [MPa] : Unit [ deg.] : Unit [rpm] : Unit [ C] : Unit [ deg.] : Unit [MPa] : Unit [MPa/ deg.] : Unit [MPa/rpm] : Unit [MPa/ C] : Unit [MPa/ deg.] : Unit [MPa/MPa] : Unit [MPa]

The cylinder differential pressure (press_dt) is corrected based on the cylinder differential pressure and the rising speed of the lift arm. Linear interpolation is applied except for the specified points. Values are subject to the data sheet.
: Unit [MPa]

3) Cancel operation: q When the cancel switch is pressed during the display holding time of the calculated weight, the load of the calculated weight is regarded as not loaded and the calculated weight data is discarded. q In this case, both of the Total loaded weight (or remaining target weight) and the addition (or subtraction) value calculated this time are cancelled and return to their previous values. 4) The total loaded weight (or remaining target weight) is indicated above the dump body illustration to the left. 1] Display items in addition mode q The measured weight is added and resultant total weight is displayed. For the addition display and data saving, see the following. Calculation for one loading: Only the calculation result is indicated. When the display of calculated weight is cleared (at the end of 15 seconds of cancel period with the cancel switch), the addition weight is accepted. Cancel of displayed value (total weight): Press the cancel switch. Total weight displayed after subtotal switch is pressed: Value of 0 (ton) is displayed. a Reset operations of total weight data and subtotal weight data are not interconnected. Display unit: ton (SI unit) : To change the unit to short ton, select ST (short ton) in the unit setting screen (available only when ENGLISH is selected for language). Calculation unit
Calculation weight is indicated in increments of 0.01 ton. The calculation value is rounded to the nearest whole number when it is displayed 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 displayed. q Calculation in subtraction mode

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The measured weight is subtracted from the initial display value, and the resultant weight is displayed. For the subtraction display and data saving, see the following. Calculation for one loading: Only the calculation result is indicated. Usually in the subtraction mode, when the display of calculated weight is cleared (at the end of 15 seconds of cancel period with the cancel switch), the subtraction weight is accepted. But if the resultant target weight is a negative value, the weight is displayed as follows. The negative values can be displayed up to "-9999 (ton)". If the resultant remaining target weight is a negative value, the negative value is displayed for three seconds, and then the remaining target weight, that has accepted before the negative value is obtained, appears and blinks. (This is called new subtraction mode.) As an exception, the load meter does not enter the new subtraction mode if following conditions are satisfied. In the case that the measured weight is 25.1 tons when the remaining target weight is 24.6 tons (displayed value is 25 tons) At this time, "-1t" is displayed above the dump body illustration, but the load meter does not enter the new subtraction mode.
When the remaining target load reaches to a negative value for the first time, the buzzer sounds for five seconds and a caution 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)

Remaining W = Remaining weight before resulting in a negative value Negative W = Measurement weight when resulting in a negative value W1 = Next measurement weight after negative result W2 = Next calculation weight after W1 In this case, the determined payload after negative weight is given as Payload at negative W measurement = Negative W - W1. Payload at W1 measurement = W1 W2. CASE 2: The remaining target weight (display weight) calculated in CASE1 is a negative value. The buzzer (B) sounds (in a tone for operational error) to warn that the target weight is reached. The buzzer does not stop sounding until the subtotal switch is pressed. CASE 3: In the case the weight display is not cancelled after the subtotal switch is pressed. The weight of the load in the bucket is determined to be the remaining weight for the next loading, and the measurement weight is used in the next subtraction. CASE 4: In the case the weight display is cancelled within 15 seconds after the subtotal switch is pressed. The load meter thinks that the bucket is emptied and new loading is performed, and displays the initial value for the remaining target weight. q The symbol shown in the illustration is displayed on the multi monitor to warn the overloading (the buzzer sounds).

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 - ((Negative W) - (W1 + W2 + ))

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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 buzzer beeps. [Note] You must press the switch for 2 seconds or more to accept the clear operation. 6) Memory capacity: The total loading weight (weight displayed on the dump body illustration) is updated and saved every time. Note that the data is saved material. 2. Change of calculation data display on load meter

1. Material selector SW 2. Addition/subtraction selection switch 1) Display switching by using load meter selection switch 1] Switching material display q Each time the material selector switch is pressed, the material display changes in turn as AoBoCoDoEoAoBoCo. 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 total 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 selection.) (The target value is already set, the target setting screen is not displayed.) Pressing the material setting switch changes the display of the next material. If the target is set, that material is accepted for the display. if not, that material is not accepted until the target value input finishes. 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.

The load meter display can be switched by using the load meter selector switch and from the multi monitor. q If "No Load Meter" is selected for the load meter setting in the Option Setting of the multi-monitor, the operations of material selection switch, addition/subtraction selection switch, subtotal switch, and cancel switch are not accepted. Load meter selector switch
q

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2] Switching calculation mode between addition and subtraction modes q Select the addition mode or the subtraction mode for each material. q When subtraction mode is switched to addition mode The total weight (weight displayed above the dump body illustration) is displayed while the subtraction target is saved. The buzzer sounds (in confirmation tone) at this time. However, if returning to the addition mode while the target value is not set, the multi-monitor thinks that the target setting screen is cancelled and sounds the buzzer (in cancel tone). q When addition mode is switched to subtraction mode The multi-monitor screen moves to the subtraction target input screen. Perform the following subtraction target input. (Set the subtraction target on the multi-monitor.) q If "Addition/subtraction switch" is pressed again on the subtraction target input screen, the addition mode continues and the buzzer sounds for 1 second (in cancel tone). q If the cancel switch is pressed on the subtraction target input screen, the addition mode continues. q When the confirmation switch is pressed on the subtraction target input screen with no target input, if no target was input in the past, the message "Wrong Setting" is displayed on the multi monitor. q When the confirmation switch is pressed on the subtraction target input screen, if any target value was input in the past, the mode switches to the subtraction mode. q While the target setting screen is displayed, 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 setting screen on the multi monitor.

3] Others If the measurement starts during target value input, the screen returns to the standard screen where the target value becomes that for the material selected for the last time. The buzzer beeps in cancel tone (for 1 second). If the input value is "0 t", the buzzer does not sound because the message "Wrong Setting" is displayed on the multi monitor. When the target value is absent, the value displayed above the dump body illustration is "0 t" and that displayed on the target value input screen is also "0 t". a For the details of target value setting screen, see the section of "Multi monitor". 3. Overload alarm q If the value set in the service mode of the multi monitor is exceeded, the following warnings are raised. 1) The display of load meter calculated weight (weight displayed above the bucket illustration) blinks. 2) The overload alarm icon on the multi monitor blinks. 3) The special alarm buzzer for overload sounds. q Resetting condition These warnings continue for 5 seconds after detection of the overload, and then are reset automatically. 4. Payload setting (setting of value for overload alarm) Payload Setting screen

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q q

q q

q q

When this screen (Payload Setting screen) is switched from the standard screen, the current payload set value is displayed. The current set value is displayed according to the information from the main monitor. "---" is displayed for the value until the set value is sent from the main monitor. If the current setting value cannot be received from the main monitor for 10 seconds or more, the screen moves to the abort screen. Pressing [F3] decrements the value by 1 [t]. Note that the switch operation is not accepted until the set value is sent from the main monitor (during "---" display). Pressing [F4] increments the value by 1 [t]. Note that the switch operation is not accepted until the set value is sent from the main monitor (during "---" display). The numeric value must not exceed the upper and lower limits of the setting range. 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 between Metric ton and US ton, the set value 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.

Default The default for the value is "99 [t]", where no warning about overload is raised. The payload set value currently displayed is accepted by pressing [F6], and the value is notified to the main monitor. After the main monitor accepts the change, the screen returns to the Adjustment Menu (Load Meter) screen. After notification of the change to the main monitor, if reception notice is not sent from the main monitor for 10 seconds or more, the screen moves to the abort screen. Note that switch operations are not accepted until the set value is sent from the main monitor (during "---" display). Pressing [F1] aborts the setting operation and the screen returns to the Adjustment Menu (Load Meter) screen.

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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. 10-217 Real-time monitor Using the real-time monitor function of the multi-monitor, the status of input and output signals of the machine monitor can be checked. q For the displayed items, see "Multi monitor", "3. Service menu, 1) Real-time monitor".
q

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Machine monitor back side

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Signal table by connector

CN-FC01 (070-20 poles) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Specifications --Power supply for clearance lamps Power supply for clearance lamps NSW power source (+24 V) NSW power source (+24 V) SW power source (+24 V) SW power source (+24 V) --GND GND D_OUT_3 (+24 V, Sink 200 mA) D_OUT_2 (+24 V, Sink 200 mA) D_OUT_1 (+24 V, Sink 200 mA) D_OUT_0 (+24 V, Sink 200 mA) Sensor power supply output (+24 V) Sensor power supply output (+5 V) GND GND GND GND I/O I I I I I I I I O O O O O O I I I I Group A A A A Form of use --+24 V power --supply +24 V power --supply +24 V continNSW power supply uous power (+24 V) supply +24 V continuNSW power supply ous power (+24 V) supply +24 V power SW power supply (+24 supply V) +24 V power SW power supply (+24 supply V) --GND GND D/O sink D/O sink D/O sink D/O sink Sensor power supply Sensor power supply GND GND GND GND GND GND ----Buzzer output 2 Buzzer (output 1) Lift arm pressure sensor power supply Lift arm angle sensor power supply GND GND GND GND I = Input WA1200-6 O = Output Remarks

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CN-FC02, CN-FC03 (070-18 poles + 12 poles) Pin No. CN-FC02 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN-FC03 1 2 3 4 5 6 7 8 9 10 11 12 D_IN_16 (24 V, 5 mA) D_IN_18 (24 V, 5 mA) D_IN_20 (24 V/GND, 5 mA) D_IN_22 (24 V/GND, 5 mA) D_IN_24 (24 V/GND, 5 mA) GND D_IN_17 (24 V/GND, 5 mA) D_IN_19 (24 V/GND, 5 mA) D_IN_21 (24 V/GND, 5 mA) D_IN_23 (24 V/GND, 5 mA) D_IN_25 (24 V/GND, 5 mA) A_IN_1(030 V) I I I I I O I I I I I I D D D D E D D D D E H D/IGND D/IGND D/IGND D/IGND D/IGND GND D/IGND D/IGND D/IGND D/IGND D/IGND A/I --D_IN_0 (24 V, 5 mA) D_IN_2 (24 V, 5 mA) D_IN_4 (24 V, 5 mA) D_IN_6 (24 V, 5 mA) D_IN_8 (24 V, 5 mA) D_IN_10 (24 V, 5 mA) D_IN_12 (24 V, 5 mA) D_IN_14 (NSW 24 V, 5 mA) GND D_IN_1 (24 V, 5 mA) D_IN_3 (24 V, 5 mA) D_IN_5 (24 V, 5 mA) D_IN_7 (24 V, 5 mA) D_IN_9 (24 V, 5 mA) D_IN_11 (24 V, 5 mA) D_IN_13 (24 V, 5 mA) D_IN_15 (24 V, 5 mA) A_IN_0 (0 to 30 V) I I I I I I I I O I I I I I I I I I B B B B B B C C B B B B B B C C H D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V A/I D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V D/I, +24 V --IGNC Specifications I/O Group Form of use

I = Input WA1200-6

O = Output Remarks

Auto-greasing input ----Load meter material selector switch input Right turn signal Service meter switch GND ----------Load meter ADDITION/SUBTRACTION mode selector switch input Left turn signal --Alternator R To check SMR with starting switch at OFF position

Air cleaner clogging 1 Air cleaner clogging 3 Parking brake emergency release signal Transmission filter clogging 1 GND --Air cleaner clogging 2 Air cleaner clogging 4 Illuminance adjustment 1 switch input Illuminance adjustment 2 switch input Clearance lamp switch

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CN-FC04, CN-FC05 (070-18 poles + 12 poles) Pin No. CN-FC04 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 CN-FC05 1 2 3 4 5 6 7 8 9 10 11 12 A_IN_2 (low resistance input) A_IN_4 (High resistance input) A_IN_6 (High resistance input) A_IN_8 (0 to 5 V) A_IN_10 (0 to 14 V) GND A_IN_3 (High resistance input) A_IN_5 (High resistance input) A_IN_7 (0 to 5 V) A_IN_9 (0 to 5 V) GND A_IN_11 (0 to 14 V) I I I I O I I I I O J J K L J J L L GND A/I A/I A/I A/I GND A/I A/I A/I A/I D_IN_26 (24 V/GND, 5 mA) D_IN_28 (24 V/GND, 5 mA) D_IN_30 (24 V/GND, 5 mA) D_IN_32 (24 V/GND, 5 mA) D_IN_34 (24 V/GND, 5 mA) D_IN_36 (24 V/GND, 5 mA) D_IN_38 (24 V/GND, 5 mA) P_IN_0(0.5 Vp-p) GND D_IN_27 (24 V/GND, 5 mA) D_IN_29 (24 V/GND, 5 mA) N.C. D_IN_33 (24 V/GND, 5 mA) D_IN_35 (24 V/GND, 5 mA) D_IN_37 (24 V/GND, 5 mA) D_IN_39 (24 V/GND, 5 mA) P_IN_1(.5 Vp-p) N.C. I I I I I I I I O I I I I I I I I E E E F F G G M E E E F F G G M D/IGND D/IGND D/IGND D/IGND D/IGND D/IGND D/IGND P/I GND D/IGND D/IGND D/IGND D/IGND D/IGND D/IGND D/IGND P/I Specifications I/O Group Form of use

I = Input WA1200-6

O = Output Remarks

Parking brake switch Hydraulic oil level Emergency steering operation/normal (common) Subtotal switch Transmission filter clogging 2 Service function 2 < switch input --GND Engine coolant level Illuminance adjustment 3 switch input --Cancel switch U switch input > switch input t switch input -----

Fuel level sensor Torque converter oil temperature sensor --Lift arm cylinder pressure sensor (head) --GND Hydraulic oil temperature sensor Brake oil temperature sensor Lift arm cylinder pressure sensor (bottom) Lift arm angle sensor GND ---

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CN-FC06 (070 12 poles) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Specifications S_NET (+) S_NET (+) CAN+ S_NET (-) S_NET (-) GND GND CAN(NC) (NC) (NC) (NC) I/O I/O I/O I/O O O O O I/O Group Form of use N N P N N P S-NET S-NET GND GND S-NET S-NET

I = Input WA1200-6 ----Communication (CAN (+)) --------Communication (CAN ()) --------I = Input I/O I/O I I I/O Group Form of use Q Q R R Q Q Q R R R TX TX RD RD WA1200-6 -----------------------------

O = Output Remarks

CN-FC07 (070 -14 poles) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 (NC) RS232C_1_CTS RS232C_1_TX RS232C_1_SG (NC) (NC) (NC) (NC) Specifications (NC) RS232C_1_RTS RS232C_1_RD (NC) (NC)

O = Output Remarks

I/O O O O O I/O

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1 Pin No. 1 2 3 4 5 6 7 8 Specifications RS232C_0_TXD FLASH SW RS232C_0_TXD (NC) RS232C_0_RXD (NC) RS232C_0_RXD GND I/O O I O I I O Group Form of use S S S S S

I = Input WA1200-6 -----------------

O = Output Remarks Without harness connection Without harness connection Without harness connection Without harness connection Without harness connection Without harness connection Without harness connection Without harness connection

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Multi-function monitor
Screen transition diagram 10-2 4

10-2 4

Outline q The multi-function monitor allows for switching the screen to the desired screens such as Maintenance Monitor screen, User Settings screen, Productivity screen, Failure Message screen, etc. by using function switches (F1 to F6) at the bottom of the screen. q When an error occurs in the machine, the multi-function monitor automatically displays the warning screen.

10-2 4 The multi-function monitor has two display modes; the normal mode for the operator in which the monitor usually stays, and the service mode for technicians in which they can check the machine data, perform various settings of the machine, and clear the machine data stored. (Input of a dedicated ID is required.) a "Main Monitor" in the figure denotes the machine monitor.

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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

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3) When alarm or error is generated

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4) Special alarm (using icon) q These alarm icons appear only in the standard screen. 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.

(*): Set bucket angle in the range from -5 to +5 degrees (in increments of one degree)is indicated here.

[3] Transmission overrun protect This icon appears and disappears according to the command from the 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 according to the command from the machine monitor, and then disappears automatically.

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2. User menus

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1) Brightness and contrast, settings q Use this menu to adjust the brightness, contrast, and backlight of the multi-function monitor.
Brightness Contrast Backlight
q

Night mode

Adjustment level 1 to 7 1 to 7 1 to 10

Default (Day) 4 4 10

Default (Night) 2 2 1

This menu allows for adjusting the brightness, 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 before moving to this screen. Press [F2] to return the current settings of brightness, contrast , and backlight to the default values. Press [F3] to reduce the level of the setting item highlighted. Press [F4] to raise the level of the setting item highlighted. Press [F5] to highlight the next setting item. (brightnessocontrastobacklightobrightness...) Press [F6] to accept the settings made in this screen and return to the standard screen. Day mode

2) Consumption q Use this menu to displays the type of selected materials, productivity (t/h) , and fuel consumption (L/h) for the specified period, and the start and end dates of the calculation of them as well. q When the display setting of the load meter is "Non-display", "----" is displayed for the Kind (of material) and Productivity, and only the value of Fuel Consumption and start and end dates are displayed. q Even if the selected kind of material is changed or the display setting of the load meter is switched between "Display" and "Non-display", the calculated data is not reset. Press [F1] to return to the standard screen. Press [F2] to move to the PRODUCTIVITY HISTORY screen. Consumption screen

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On this screen (PRODUCTIVITY HISTORY 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. The materials are highlighted in order as follows: Ao""oEoD oCoBoA. Press [F6] to move to the deletion screen of the highlighted material (including ""). (See the deletion screen) Press [F1] to move back to the Consumption screen. PRODUCTIVITY HISTORY screen

Deletion screen

3) User setting Press [F1] to return to the standard screen. Press [F3] to highlight the immediate lower setting item. When "Language" is highlighted, pressing [F3] highlights "DATE". Press [F4] to highlight the immediate upper 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 material is displayed (highlighted). Press [F2] to return to the PRODUCTIVITY HISTORY screen without deleting the information of the material. Press [F5] to reset (set to zero) the information (productivity data and fuel consumption data) of the material and set the date to blank, and to return to the Consumption screen.

a When "DATE" or "TIME", the screen switches to the same DATA SETTING screen in either case. Note that the "year" data is highlighted on the DATE SETTING screen that is opened by selecting "DATE". On the DATE SETTING screen opened by selecting "TIME", the "hour" data is highlighted.

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Date setting Press [F1] to return to the standard screen, applying the settings accepted before moving to this screen. Press [F3] to advance the respective set values (year, month, day, hour, and minute). The set value of year does not advance exceeding the upper limit. If the current set value of month is" Dec", it changes to "Jan". If the current set value of day is the last day of the current set month ("Dec 31"), it changes to the first day of the same month ("Dec 1"). If the current set value of hour is "23", it changes to "0" (zero). If the current set value of minute is "59", it changes to "0" (zero). DATE SETTING screen (immediately after being switched from previous screen by selecting "DATE")

DATE SETTING screen (immediately after being switched from previous screen by selecting "TIME")

For the set value of "Daylight Saving Time", if the current set value is "ON", pressing [F3] changes the highlighted value to "OFF", or vice versa. The triangle mark that indicates the direction in which the currently highlighted value faces the non-highlighted value (in the figure, direction in which "OFF" faces "ON") changes to the one that indicates the reverse direction. Press [F4] to turn back the numeric values (year, month, day, hour, and minute). The set value of year does not turn back exceeding the lower limit. As for Daylight Saving Time, the change in the set value is the same as that when pressing [F3]. For the set values of other than "year" and Daylight Saving Time when the set values are respective lower limit, they change in reverse to when pressing [F3]. Press [F5] to highlight the immediate 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 triangles 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 language, the daylight saving time cannot be set. DATE SETTING screen (for setting of Daylight Saving Time)

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User ID input 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 before moving to this screen. Press [F2] to delete a number entered last. If no number is entered, nothing is changed on the screen. Press [F3] to highlight a numeral on the left of the currently selected numeral (highlighted). If the currently highlighted numeral is "1", numeral "0" is highlighted. Press [F4] to highlight a numeral on the right of the currently selected numeral (highlighted). If the currently highlighted numeral is "0", numeral "1" is highlighted. Press [F5] to select the currently highlighted numeral and input it in the entry. (The numeral is input from the upper digit.) Press [F6] to accept the currently displayed ID and return to the User setting screen.

USER ID SETTING screen

Language setting When this screen is displayed first, the current set language is highlighted. Press [F1] to return to the User setting screen, applying the language accepted before moving to this screen. Press [F3] to highlight the language immediately under the currently highlighted language. If the lowermost language is highlighted at present, the uppermost language is highlighted. Press [F4] to highlight the language immediately above the currently highlighted language. If the uppermost language is highlighted at present, the lowermost language is highlighted. Press [F6] to accept the currently highlighted language and return to the User setting screen.

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Language setting screen

(Title display) The screen title is displayed in English and the language names that are currently available are expressed in respective languages. The titles are displayed as follows: Available languages are expressed in "respective local languages" and the screen title is expressed as "Language" Main SCREEN select screen When this screen is displayed first, the current setting is highlighted. Press [F1] to return to the User setting screen, applying the setting accepted before moving to this screen. Press [F3] to highlight the setting under the currently highlighted setting. If the lowermost setting is highlighted at present, the uppermost setting is highlighted. Press [F4] to highlight the setting immediately above the currently highlighted setting. If the uppermost setting is highlighted at present, the lowermost setting is highlighted. Press [F6] to accept the currently highlighted setting and return to the User setting screen. Main SCREEN Select screen

a When the starting switch is turned to OFF position, the current selection of the main screen is saved. When the starting switch is turned to ON position again, the main screen is displayed according to the saved selection. Type and specification of main screen 1] Standard Logo "KOMATSU" is displayed.

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2] Option 1

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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 load A = 0.37 (f = 0.16 [Hz]) Set value of traveling load A = 0.37 (f = 0.16 [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

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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.

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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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4) Maintenance monitor q Use the MAINTENANCE MONITOR screen to display the remaining time to maintenance. Press [F1] to return to the standard 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. 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 highlighted 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 2)

(page 3)

(page 4)

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On the maintenance time reset screen, press [F2] to return to the original screen without resetting the remaining maintenance time. On the maintenance time reset screen, press [F5] to reset the remaining maintenance time and return to the original screen. Maintenance time reset screen

6) Load meter menu a "Main Monitor" in the figure denotes the machine monitor. The PRODUCTION SUMMARY screen displays following productivity data by each type of material (A to E) and the total. 1] Number of loading times 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 material A is highlighted. Press [F3] to highlight the lower material. The materials are highlighted in order as follows: AoBoCoDoEoTOTALoA Press [F4] to highlight the upper material. The materials are highlighted in order as follows: AoTOTALoEoDoCoBoA Press [F6] to move to the deletion screen for the material (including TOTAL) highlighted at present. (See the deletion screen.) Press [F1] to return to the standard screen. Press [F2] to move to the Load Meter Menu screen. (See the Load Meter Menu screen.) PRODUCTION SUMMARY screen

5) Failure message This screen displays the occurrent failures. The serial number, 6-digit failure code, failure details, and occurred time are displayed on the screen. The total number of failure occurrences is displayed at the upper right. Press [F1] to return to the standard screen. Press [F2] to jump to the next page. Press [F3] to scroll down the page by one record. Press [F4] to scroll up the page by one record. Press [F5] to jump to previous page. FAILURE Message screen

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When this deletion screen is displayed first, only the information about the selected material is displayed (highlighted). Press [F2] to return to the PRODUCTION SUMMARY screen without deleting the material. Press [F5] to reset (set to zero) the information (number of loading times, total loading weight) of the material, to update the last reset date, and to return to the PRODUCTION SUMMARY screen. Note: When this screen is displayed after selecting TOTAL, the information (number of loading times and total loading weight) of all materials is reset (set to zero) and the last reset date is updated. (The last reset dates of the materials A to E and TOTAL become the same at this point.) Deletion screen

Note: The menu of "Subtraction Mode Target Setting" appears only when the subtraction mode is selected in the main monitor. The current set value is also displayed if the target is set. When it is not set yet, "0 t" is displayed for the value. When the mode is changed from the subtraction to addition mode in the main monitor while the "Subtraction Mode Target Setting" is highlighted on this screen, the menu of "Subtraction Mode Target Setting" disappears from the screen and the uppermost menu of "No-Load Calibration" is highlighted. When the kind of material to be applied to the subtraction mode is changed, the set value displayed on this screen is changed to that of the changed material type. When "Non-display" is selected for the display setting of the load meter, the menu configuration is the same as that for 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. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. If the uppermost menu is highlighted, 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 information, refer to the description of the screen.)

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Load Meter Menu screen

After reading the message, press [F5] to move to the Load Meter Menu screen. Abort confirmation screen of No-Load Calibration

*: 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. The allowable setting range of the reference load for the on-load calibration is between 1.0 and 99.0 t and inputting the data out of the allowable setting range moves the screen to the setting error screen. a) No-Load Calibration After moving to this screen, the screens are switched sequentially according to the commands from the main monitor. When this calibration ends successfully, the screen returns to the Load Meter Menu screen. When this calibration aborts, the screen moves to the abort confirmation screen. Press [F1] to cancel the no-load calibration and move to the abort confirmation screen. When the no-load calibration is canceled, the main monitor disregards the current calibration and revert the calibration data back to the original data. No-Load Calibration screen

b) On-Load Calibration If this calibration ends successfully, the screen returns to the Load Meter Menu screen. When this calibration aborts, the screen moves to the abort confirmation screen. The main monitor issues the command to move to next screen when the calibration aborts. After the transition, the multi-function monitor (KOMTRAX Plus) performs the processing. Press [F1] to cancel the on-load calibration and move to the abort confirmation screen. When the on-load calibration is canceled, the main monitor disregards the current calibration result and revert the calibration data back to the original data.

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On-Load Calibration screen

Load weight input screen

When this screen is displayed first, the initial load weight is displayed according to the information from the main monitor. The input place that is currently available is highlighted. The current input position is kept blank and no operation is accepted because of working out the average of calibraion until the data is received. The input format is "**.* t". Example: To input "5.3 t", enter "05.3". Press [F1] to move to the on-load calibration cancel screen. Press [F2] to move the highlighted input place to the left by one. If the foremost input place is highlighted, the highlighted place does not move. Press [F3] to change the figure in the highlighted place in the order of: 9o8o7o6o5o4o3o2o1o0o9. Press [F4] to change the figure in the highlighted place in the order of: 1o2o3o4o5o6o7o8o9o0o1. 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 highlight the foremost input place.

*: Setting range: 1.0 to 99.0 Press [F2] to return to the load weight input screen. When the load weight input screen is displayed, the screen shows the same numeric value in the input field as that on the screen before moving to this load weight confirmation screen, and highlights the foremost input place. Press [F5] to accept the load weight entered. When the load weight is accepted, the multi-function monitor informs the main monitor of the load weight accepted. The main monitor receives the accepted load weight and informs the multi-function monitor of the reception. When the multi-function monitor receives the notice, the screen moves to the setting completion screen. When the multi-function monitor determines that the main monitor did not set the load weight properly, the screen moves to the abort screen. Load weight confirmation screen

Press [F1] to move to the Load Meter Menu screen.

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Load weight confirmation screen (setting completion screen)

On-load calibration cancel screen

This screen is the same as the load weight input screen except that the message "Incorrect Setting" is displayed. Load weight input screen (screen for warning about incorrect setting and prompting re-entry)

After reading the message, press [F5] to move to the Load Meter Menu screen. Abort confirmation screen of on-load calibration

Press [F2] to return to the load weight input screen. When the load weight input screen is displayed, the screen shows the same numeric value in the input field as that sent from the main monitor when this screen was switched from the On-Load Calibration screen, and highlights the foremost input place. Press [F5] to cancel the on-load calibration result and return to the Load Meter Menu screen. If the calibration is discontinued, the main monitor ignores the calibration of this time.

c) Calibration Reset Press [F2] to return to the Load Meter Menu screen without resetting the calibration. Press [F5] to send the reset signal to the main monitor. The main monitor receives the reset signal and informs the multi-function monitor of the reception. When the multi-function monitor receives the notice, the screen moves to the setting completion screen. Note: When the calibration is reset, the data of both no-load and on-load calibrations is reset.

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Calibration reset screen

Load meter display setting selection screen

Press [F1] to move to the Load Meter Menu screen. Calibration reset screen (Setting completion screen)

e) Subtraction Mode Target Setting When this screen is displayed first, the target weight is displayed according to the information from the main monitor. The input place that is currently available is highlighted. (When this screen is displayed first, the foremost 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". Press [F1] to move to the Load Meter Menu screen. Press [F2] to move the highlighted input place to the left by one. If the foremost input place is highlighted, the highlighted place does not move. Press [F3] to change the figure in the highlighted place in the order of: 9o8o7o6o5o4o3o2o1o0o9. Press [F4] to change the figure in the highlighted place in the order of: 1o2o3o4o5o6o7o8o9o0o1. 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 setting completion 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.

d) Load Meter On/Off Selection Press [F6] to send the notice of change in the setting to the main monitor. When the main monitor receives this change 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 screen.

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Subtraction Mode Target Setting screen

Subtraction Mode Target Setting screen (setting completion screen)

*: Setting range: 1 to 99999 Operations to display the Subtraction Mode Target Setting screen 1] Selecting "Subtraction Mode Target Setting" on the Load Meter Menu screen. 2] Changing the mode of load meter from Addition to Subtraction by using the load 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 material 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 Target Setting screen in the following cases: q When you are in the service mode q When the maintenance time is reset, the productivity history is cleared, and the production summary is reset q When you are in the Load Meter Menu screen and subsequent screen q When an emergency warning is displayed (However, if all errors are cancelled, the screen is displayed.) Press [F1] to return the Load Meter Menu screen. This screen is the same as the target weight input screen except that the message "Incorrect Setting" is displayed. Subtraction Mode Target Setting screen (screen for warning about incorrect setting and prompting re-entry)

Press [F5] to move to the load meter menu screen. The main monitor issues the command to move to this screen when the calibration aborts. After the transition, the multi-function monitor (KOMTRAX Plus) performs the processing. After reading the message, press [F5] to move to the Load Meter Menu screen. (This is common to all abort screens.)

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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.)

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3. Service menu How to enter into the service menu

(*1) When this screen is displayed first, numeral "1" is highlighted. Press [F1] to return to the User setting screen. Press [F2] to delete a figure entered last. When no figure entered, the screen display does not change. 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.

If the ID is wrong, the screen does not change. Use [F2] to delete the wrong ID and enter the correct ID so that the screen moves to the service menu screen. Or, press [F1] to return to the User setting screen, and then enter this screen again to input the correct ID.

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a Two types of ID are provided: the usual ID and special ID that allows for entering the special optional menu. The entry of the special ID allows you to enter the special optional menu "Engine mode" in addition to the menus that are allowed by entry of the usual ID. Service password: 7823401300 Special password: 3287040031 (*2) When this screen (SERVICE MENU SELECT screen) is displayed first, the menu item of Real Time Monitor is highlighted. Press [F3] to highlight the lower menu. (Scroll function) If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. (Scroll function) If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return to the standard screen. Press [F6] to move to the execution screen of the menu highlighted at present. (For more information, refer to the description of the screen.)

1) Real time monitor When this screen (REAL TIME MONITOR screen (for selection of controller)) is displayed first, the menu item of Main Monitor is highlighted. Press [F3] to highlight the lower controller. If the lowermost controller is highlighted, pressing [F3] highlights the uppermost controller. Press [F4] to highlight the upper controller. If the uppermost controller is highlighted, pressing [F4] highlights the lowermost controller. Press [F1] to move back to the SERVICE MENU SELLECT screen. Press [F6] to move to the REAL TIME MONITOR screen of the controller highlighted at present. (For more information, refer to the description of the screen.) REAL TIME MONITOR screen (for selection of controller)

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Press [F1] to return to the REAL TIME MONITOR screen (for selection of controller). Press [F2] to move to the next page. Press [F5] to move to the previous page. While "PAUSE" button is displayed, press [F3] to hold the values being displayed. (The button indication changes to "RESET".) While "RESET" button is displayed, press [F3] to release the values being held. (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 monitor)

As the engine has 16 cylinders, in order to check the exhaust gas temperature of 16 cylinders at the same time, a special screen " Exhaust gas temperature list" is provided. If the menu of "6 ITEMS" is selected, desired cylinders can be specified (each cylinder has an ID) to check the exhaust gas temperature of individually. To check exhaust gas temperature of all cylinders at once, use the real time monitor function of the engine controller.

When this screen (REAL TIME MONITOR (6 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. (The button indication changes to "PAUSE".) Press [F6] to move to the ID input screen for the cylinder specified in the row highlighted at present.

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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.) Press [F2] to move the highlighted input place to the left by one. If the foremost place is highlighted, the highlighted place does not move. Press [F3] to change the figure in the highlighted place in the order of: 9o8o7o6o5o4o3o2o1o0o9. Press [F4] to change the figure in the highlighted place in the order of: 1o2o3o4o5o6o7o8o9o0o1. Press [F5] to move the highlighted input place to the right by one. If the last input place is highlighted, pressing [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 monitoring 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

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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 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 1 1 2 2 2 2 2 3 3 3 3 3 3 4 4 5 5 5 5 5 5 6 6 7 7 7 7 7 7 20200 20221 20222 01001 40012 04202 04200 04103 04408 04409 04401 04404 30201 30204 04302 40200 06001 06003 40400 40402 40500 40501 40600 40800 40900 40901 40902 40903 40904 40925 MONITOR PROG P/N VERSION(APP) VERSION(DATA) ENGINE SPEED VEHICLE SPEED FUEL SENSOR FUEL SENSOR COOLANT TEMP T/C TEMP T/C TEMP HYD. OIL TEMP HYD. OIL TEMP BRAKE OIL TEMP BRAKE OIL TEMP ALTERNATOR R SMALL LAMP BOOM ANGLE BOOM ANGLE BOOM BOTTOM PRESSURE BOOM BOTTOM PRESSURE BOOM HEAD PRESSURE BOOM HEAD PRESSURE CAL PRESSURE MEASURED LOAD D-IN 0-7 D-IN 8-15 D-IN 16-23 D-IN 24-31 D-IN 32-39 D-OUT 0-3 ------1 rpm 0.1 km/h 1% 0.01V 1 C 1 C 0.01 V 1 C 0.01 V 1 C 0.01 V 0.1 V 0.1 V 1 deg. 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.01 t ------------10-digit part No. is displayed. 01010101 01010101 04000 0.050.0 0100 0.05.0 -40210 24131 0.005.00 24131 0.005.00 24131 0.005.00 0.030.0 0.030.0 -9090 0.005.00 0.0050.00 0.005.00 0.0050.00 0.005.00 0.0050.00 0.0050.00 01010101 01010101 01010101 01010101 01010101 01010101 Source: engine controller Source: transmission controller

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KOMTRAX Plus controller Monitor No. screen ID No. page

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 1 1 1 1 2 2 2 2 3 3 3 3 3 3 4 4 4 4 5 5 5 6 37501 37504 99701 99700 04304 99703 99702 99705 99704 32601 32602 32603 32604 29700 29701 92800 92802 92801 92803 40303 40304 40305 40944

Item

Data unit
1 C 0.01 V 0.01 MPa 0.01 V 0.1 V 0.01 MPa 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.0 1V 0.01 MPa 0.01 V

Data display range (example)(*)

-30100 0.005.00 0.0050.00 0.005.00 0.030.0 0.0050.00 0.005.00 0.0050.00 0.005.00 0.0050.00 0.005.00 0.0050.00 0.005.00 0.0050.00 0.005.00

Remarks

AMBIENT AIR TEMP AMBIENT AIR TEMP PPC. OIL PRESSURE PPC. OIL PRESSURE Charged Amount T/M MAIN PRESSURE T/M MAIN PRESSURE T/M LUB PRESSURE T/M LUB PRESSURE T/C IN PRESSURE T/C IN PRESSURE TC OUT PRESSURE TC OUT PRESSURE S/T PUMP PRESSURE S/T PUMP PRESSURE F BRAKE OIL PRESSURE F BRAKE OIL PRESSURE R BRAKE OIL PRESSURE R BRAKE OIL PRESSURE BATTERY LEVEL 1 BATTERY LEVEL 2 BATTERY LEVEL 3 D-IN 0-7

0.01 MPa 0.0050.00 0.01 V 0.005.00

0.01 MPa 0.0050.00 0.01 V 0.01 V 0.01 V 0.01 V --0.005.00 0.005.00 0.005.00 0.005.00 01010101 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero. 01010101 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero. 010 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero. 0101 ["1" or "0" in the corresponding digit (number)] 1: output signal ON, 0: output signal OFF, unused part is also zero. 0101 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero.

Outputs the input signals intact of D_IN_0 to D_IN_7

24

40945

D-IN 8-15

---

Outputs the input signals intact of D_IN_8 to D_IN_15

25

40972

D-IN 16-18

---

Outputs the input signals intact of D_IN_16 to D_IN_18 Outputs the output signals intact of D_OUT_0 to D_OUT_3 Outputs the input signals intact of SEL_0 to SEL_3

26

40948

D-OUT 0-3

---

27

40947

D = SOL 0-3

---

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Engine controller Monitor No. screen ID No. page

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 1 1 1 1 1 2 2 2 2 3 4 4 4 5 5 5 5 6 6 6 6 7 7 7 7 8 8 8 8 01002 04102 42700 36400 42801 36501 37200 43800 37400 37300 42614 42615 42616 42617 42618 42619 42620 42621 42622 42623 42624 42625 42626 42627 42628 42629 42630 42631 42632

Item
ENGINE SPEED COOLANT TEMP ENGINE OIL TEMP Common RAIL PRESSURE BLOW BY PRESSURE BOOST PRESSURE ENGINE OIL PRESSURE ENGINE OIL LEVEL ATMOSPHERE PRESSURE FUEL Consump EXHAUST GUS TEMP Ave. EXHAUST GUS TEMP R AVERAGE EXHAUST GUS TEMP L AVERAGE EXHAUST GUS TEMP R1 EXHAUST GUS TEMP R2 EXHAUST GUS TEMP R3 EXHAUST GUS TEMP R4 EXHAUST GUS TEMP R5 EXHAUST GUS TEMP R6 EXHAUST GUS TEMP R7 EXHAUST GUS TEMP R8 EXHAUST GUS TEMP L1 EXHAUST GUS TEMP L2 EXHAUST GUS TEMP L3 EXHAUST GUS TEMP L4 EXHAUST GUS TEMP L5 EXHAUST GUS TEMP L6 EXHAUST GUS TEMP L7 EXHAUST GUS TEMP L8

Data unit
1 rpm 1 C 1 C 0.01 MPa 0.01 kPa 1 kPa 1 kPa --1 kPa 0.1 l/h 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C

Data display range (example)(*)

08031 -2731735 -40210 0250.00 -250251.99 0500 01000 OK (normal), NG (defective) 0125 0.03212.8 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735 -2731735

Remarks
CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 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.

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Transmission controller No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Monitor screen page

1 1 1 2 2 2 2 2 3 3 3 3 4 4 4 4 4 4 5

ID No.
20201 20223 20224 41600 92502 31400 93900 01008 41203 41201 41202 93700 93600 93601 93602 93603 92400 92401 95500

Item
T/M PROG P/N T/M VERSION(APP) T/M VERSION(DATA) ENGINE MODE Mod/C SPEED: OUT

Data details
Part number of mass production software Software version (software logic part version) Software version (software data part version) Engine mode for engine output control Modulation clutch output speed

Data unit (and range)

10-digit number (78**-**-****) According to the software version According to the software version 0: Torque curve H 1: Torque curve M 2: Torque curve L x1[min-1] (032767[min-1]) x1[min-1] (032767[min-1]) x1[min-1] (032767[min-1]) x1[min-1] (032767[min-1]) x0.001[MPa] (05[MPa]) x0.001[MPa] (05[MPa]) x0.001[V] (05[V]) x1[%] (0100[%]) x1[ C] (0150[ C]) x1[mV] (0.005.00[V]) x1[ C] (0150[ C]) x1[mV] (0.005.00[V]) x1[MPa] (0.005.00[MPa]) x1[mV] (0.005.00[V]) 0: RPM set switch OFF 1: PRM set switch ON

Remarks

For WA1200, 1: Torque curve M is not used.

T/M SPEED: OUT Transmission output shaft speed TIRE FR SPEED ENGINE SPEED T/M CUT OFF SET PRESSURE T/M CUT OFF PRESSURE T/M CUT OFF PRESSURE Front left tire speed Engine speed Reduced transmission cutoff set pressure (IN pressure) Reduced brake oil pressure Input voltage of brake pressure

T/C SPEED RATIO Torque converter speed ratio T/M OIL TEMP T/M OIL TEMP T/M OIL TEMP2 T/M OIL TEMP2 MOD/C PRESSURE MOD/C PRESSURE Transmission oil temperature (A_IN_1) Input voltage of transmission oil temperature (A_IN_1) Transmission oil temperature (A_IN_3) Input voltage of transmission oil temperature input (A_IN_3) Oil pressure equivalent to modulation clutch pressure input (A_IN_7) Voltage value of modulation clutch pressure input (A_IN_7)

THROTTLE LOCK Status of input signal A THROTTLE LOCK Status of input signal B THROTTLE LIMIT Command value for lower limit of LO throttle position TRACTION DIAL TRACTION DIAL SPEED DIAL SPEED DIAL ECMV 1 DIR ECMV 2 DIR ECMV 3 DIR ECMV F DIR ECMV R DIR Set value of traction dial Input voltage of set value from traction dial Set value of speed control dial Input voltage of set value from speed control dial Current value of ECMV output command to 1st clutch Current value of ECMV output command to 2nd clutch Current value of ECMV output command to 3rd clutch Current value of ECMV output command to FWD clutch Current value of ECMV output command to REV clutch

Because of detection at analog port

20

95501

21 22 23 24 25 26 27 28 29 30

5 6 6 6 6 7 7 7 7 7

44201 94000 94001 40014 40015 31602 31603 31604 31608 31606

0: PRM set auto-deceleraBecause of tion switch OFF detection at ana1: PRM set auto-deceleralog port tion switch ON x0.1[%] (0.0100.0[%]) x1[%] (0100[%]) x1[mV] (0.005.00[V]) x1[km/h] (312[km/h]) x1[mV] (0.005.00[V]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA])

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No.
31 32 33 34 35 36 37 38 39 40 41

Monitor screen page

7 8 8 8 8 8 9 9 9 9 9

ID No.
31640 41802 41803 41804 41808 41806 40905 40906 40907 40908 40942

Item
ECMV MOD/C DIR FILL TIME 1 FILL TIME 2 FILL TIME 3 FILL TIME F FILL TIME R D-IN 0-7 D-IN 8-15 D-IN 16-23 D-IN 24-31 D-IN 32-39

Data details
Current value of ECMV output command to modulation clutch Fill time of 1st clutch (at last gear shifting) Fill time of 2nd clutch (at last gear shifting) Fill time of 3rd clutch (at last gear shifting) Fill time of FWD clutch (at last gear shifting) Fill time of REV clutch (at last gear shifting) Status of input signal Status of input signal Status of input signal Status of input signal Status of input signal ON/OFF output from SOL_OUT0 to 7. '0' indicates that drive current is output. ON/OFF output from SOL_OUT8 to 11B. '0' indicates that drive current is output. ON/OFF output from SOL_OUT2 to 3, SW_OUT0 to 1, and BATT_RY_OUT. '0' indicates that drive current is output.

Data unit (and range)

x1[mA] (01000[mA]) x0.01[sec] (0 to 2.55 [sec], 0: no fill) x0.01[sec] (0 to 2.55 [sec], 0: no fill) x0.01[sec] (0 to 2.55 [sec], 0: no fill) x0.01[sec] (0 to 2.55 [sec], 0: no fill) x0.01[sec] (0 to 2.55 [sec], 0: no fill) 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 11-digit number indicates learning flags for clutches in the following order: [FFFRRR11123] Learned: 1, Not learned: 0 F, R, and 1st clutches have 3 flags depending on learning conditions starting from the left: engine speed Z 875 rpm, 875 to 1200 rpm, and engine speed X 1200 rpm Learning flags for 2nd and 3rd clutches do not depend on engine speed. x0.1[ deg.] (-25.025.0[ deg.]) x1[mV] (0.005.00[V]) x0.1[ deg.] (-25.025.0[ deg.]) x1[mV] (0.005.00[V]) x1[MPa] (0.0050.00[MPa]) x1[mV] (0.005.00[V]) x1[MPa] (0.0050.00[MPa]) x1[mV] (0.005.00[V])

Remarks

Fix to 0 for unused ports 33 to 39.

42

10

40949

D-OUT 0-7

43

10

40950

D-OUT 8-15

44

10

40951

D-OUT 16-23

45

11

94100

Trigger learning Flag

Status of trigger time initial learning flag for each clutch [F, F, F, R, R, R, 1, 1, 1, 2, 3]

11-bit data in order of FFFRRR11123 is displayed on multi-function monitor.

46 47 48 49 50 51 52 53

11 11 11 11 12 12 12 12

32900 32902 32904 32905 35500 35504 35501 35505

ANGLE SENSOR(FR) ANGLE SENSOR(FR) ANGLE SENSOR(LR) ANGLE SENSOR(LR) BRAKE OIL PRESSURE F BRAKE OIL PRESSURE F BRAKE OIL PRESSURE R BRAKE OIL PRESSURE R

Inclination angle equivalent to pitch angle sensor input (A_IN_9) Voltage value of pitch angle sensor input (A_IN_9) Inclination angle equivalent to pitch angle sensor input (A_IN_9) Voltage value of pitch angle sensor input (A_IN_9) Oil pressure value equivalent to brake oil pressure sensor input (A_IN_15) Voltage value of brake oil pressure sensor input (A_IN_15) Oil pressure value equivalent to brake oil pressure sensor input (A_IN_16) Voltage value of brake oil pressure sensor input (A_IN_16)

Value not filtered

Value not filtered

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Work equipment controller Monitor No. screen page

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5 5

ID No.

Item

Data details

Data unit (and range)

Remarks

20202 20225 20226 41900 41909 41901 41910 41902 41911 41903 41912 42000 42001 42002 42003 06002 06005 42100

19 20 21 22 23 24 25 26 27 28 29 30

5 5 6 6 6 6 6 7 7 7 7 7

42101 94600 94300 94301 94400 94401 41908 94700 94701 40401 40402 94800

10-digit number (78**-**-****) According to software version According to software version x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x1[mA] (01000[mA]) x0.01[V] (0.005.00[V]) x0.01[V] (0.005.00[V]) x0.01[V] (0.005.00[V]) x0.01[V] (0.005.00[V]) x0.1[deg] BOOM ANGLE Calculated lift arm angle (-60.0+60.0[deg]) Input voltage value from lift arm x0.01[V] BOOM ANGLE angle sensor potentiometer (0.005.00[V]) The number of lift arm lever 0 to 256000 (in increments BOOM LEVER operations expressed in increof 1000 operations) ments of 1000 operations The number of bucket lever 0 to 256000 (in increments BUCKET LEVER operations expressed in increof 1000 operations) ments of 1000 operations x1[cc/rev] PUMP FLOW Calculated pump delivery (150830[cc/rev]) AJSS lever angle equivalent to x0.1[deg] AJSS LEVER AJSS lever potentiometer input (-60.0+60.0[deg]) Input voltage value from AJSS x0.01[V] AJSS LEVER lever potentiometer (0.005.00[V]) Frame angle equivalent to x0.1[deg] FRAME ANGLE AJSS frame potentiometer (-60.0+60.0[deg]) input Input voltage value from AJSS x0.01[V] FRAME ANGLE frame potentiometer (0.005.00[V]) Command current to AJSS x1[mA] AJSS EPC DIR EPC (01000[mA]) Reduced loader pump presx0.01[MPa] LO PUMP PRESSURE sure (056.3[MPa]) Input voltage value of loader x0.001[V] LO PUMP PRESSURE pump pressure (05[V]) BOOM BOTTOM Reduced lift arm cylinder bot- x0.01[MPa] PRESSURE tom pressure (050[MPa]) BOOM BOTTOM Input voltage value of lift arm x0.001[V] PRESSURE cylinder bottom pressure. (05[V]) Deviation between AJSS frame x0.1[deg] S/T DEFLECTION potentiometer angle and AJSS (0.0+120.0[deg]) lever angle BBC PROG P/N

Part number of mass production software Software version (software BBC VERSION(APP) logic part version) Software version (software BBC VERSION(DATA) data part version) Command current value to lift RAISE EPC DIR 1 arm RAISE EPC Command current value to lift RAISE EPC DIR 2 arm RAISE EPC Command current value to lift LOWER EPC DIR 1 arm LOWER EPC Command current value to lift LOWER EPC DIR 2 arm LOWER EPC Command current value to TILT EPC DIR 1 bucket TILT EPC Command current value to TILT EPC DIR 2 bucket TILT EPC Command current value to DUMP EPC DIR 1 bucket DUMP EPC Command current value to DUMP EPC DIR 2 bucket DUMP EPC Input voltage value from lift arm BOOM POT1 lever potentiometer 1 Input voltage value from lift arm BOOM POT2 lever potentiometer 2 Input voltage value from bucket BUCKET POT1 lever potentiometer 1 Input voltage value from bucket BUCKET POT2 lever potentiometer 2

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Monitor No. screen page

31 32 33 34 35 7 8 8 8 8

ID No.

Item

Data details
Status of digging-in-progress flag Status of input signal Status of input signal Status of input signal Status of input signal

Data unit (and range)

1: ON (when in digging 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 1: ON, 0: OFF(OPEN) Applied to each bit

Remarks

94900 40910 40911 40912 40913

WORK FLAG D-IN 0-7 D-IN 8-15 D-IN 16-23 D-IN 24-31

36

40961

D-IN 32-39

Status of input signal

Input signals 33-39 without port are fixed at 0 to simplify communication information.

37

40952

D-OUT 0-7

38

40953

D-OUT 8-15

39

40954

D-OUT 16-23

ON/OFF output from SOL_OUT0 to 7. '0' indicates that drive current is output. ON/OFF output from SOL_OUT8 to 11B. '0' indicates that drive current is output. ON/OFF output from SIG_OUT2 to 3, HSW_OUT0 to 1, and BATT_RY_OUT '0' indicates that drive current is output.

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

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2) PM clinic Press [F1] to return SERVICE MENU SELECT screen. Press [F2] to move to the previous page. If current page is page 1, pressing [F2] moves the screen to page 4. Press [F5] to move to the next page. If current page is page 4, pressing [F5] moves the screen to page 1. While "PAUSE" button is displayed, press [F3] to hold the values being displayed. (The button indication changes to "RESET".) While "RESET" button is displayed, press [F3] to release the values being held. (The button indication changes to "PAUSE".) For information on the items displayed in each page, refer to the table. PM-CLINIC MENU screen (page 1)

PM clinic item Page 1/4 1/4 1/4 1/4 2/4 2/4 2/4 2/4 2/4 2/4 3/4 3/4 3/4 3/4 3/4 3/4 4/4 4/4 4/4 4/4 4/4 4/4 Component in charge of detection ENGINE Engine con2 seconds rpm SPEED troller ENGINE OIL Engine con2 seconds kPa PRESSURE troller ENGINE OIL Engine con2 seconds degC TEMP troller COOLANT Engine con2 seconds degC TEMP troller ENGINE Engine con2 seconds rpm SPEED troller BLOW-BY Engine con2 seconds kPa PRESSURE troller BOOST PRUSEngine con2 seconds kPa SURE troller EXH GAS Engine conTEMPERA2 seconds degC troller TURE AMBIENT AIR KOMTRAX 2 seconds degC TEMP Plus Common Rsil Engine con2 seconds MPa Pressure troller T/C TEMP 2 seconds degC Main moniter T/C IN PRESKOMTRAX 2 seconds MPa SURE Plus T/C OUT KOMTRAX 2 seconds MPa PRESSURE Plus T/M MAIN KOMTRAX 2 seconds MPa PRESSURE Plus T/M LUB KOMTRAX 2 seconds MPa PRESSURE Plus TransmisT/M MOD 2 seconds MPa sion controlPRESSURE ler Main HYD. OIL 2 seconds C TEMP monitor PPC. OIL KOMTRAX 2 seconds MPa PRESSURE Plus Work equipHYD.OIL 2 seconds MPa ment controlPRESSURE ler S/T PUMP KOMTRAX 2 seconds MPa PRESSURE Plus F BRAKE OIL KOMTRAX 2 seconds MPa PRESSURE Plus R BRAKE OIL KOMTRAX 2 seconds MPa PRESSURE Plus Item name Sampling time Unit

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3) Failure history This screen displays the failure history. On this screen, the serial number, 6-digit failure code, brief explanation of failure, the number of failure occurrence, and the date of first and last occurrences of detected failure are displayed. The total of failure records number is indicated 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. (However, the record in KOMTRAX Plus is held.) FAILURE HISTORY screen

4) Snapshot Press [F1] to return the SERVICE MENU SELECT screen. Press [F6] to move to the snapshot trigger confirmation screen. SNAPSHOT TRIGGER screen

Press [F2] to return to the SNAPSHOT TRIGGER screen. Press [F5] to start the snapshot. (The screen changes the snapshot execution screen.) Snapshot trigger confirmation screen

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Press [F1] to move to the snapshot cancel screen. After 7 minutes 30 seconds elapsed, the screen automatically switches to the snapshot exit screen. Snapshot execution screen

Snapshot exit screen

Press [F1] to return the SERVICE MENU SELECT screen. Press [F6] to move to the snapshot trigger confirmation screen. Snapshot cancel screen

5) Adjustment When this screen (Adjustment Menu screen) is displayed first, the menu of "Load Meter" is highlighted. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return the SERVICE MENU 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 SNAPSHOT TRIGGER screen.

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When this screen (Adjustment Menu (1) Load Meter screen) is displayed first, the menu of "Boom Angle Sensor (Upper)" is highlighted. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return to the Adjustment Menu screen for menu selection. 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 (1) Load Meter screen

Adjustment Menu (2) AJSS screen

When this screen (Adjustment Menu (2) AJSS screen) is displayed, the menu of "AJSS Neutral Position Adjustment" is highlighted. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to move back to the adjustment menu selection 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.)

When this screen (Adjustment Menu (3) Work Equipment screen) is displayed, the menu of "Boom Ang. Sensor (Upr) (Eqp. Ctrl) Adj." is highlighted. Press [F3] to highlight the lower menu. (Scroll function) If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. (Scroll function) If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to move back to the adjustment menu selection 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 (3) Work Equipment screen

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When this screen (Adjustment Menu (4) T/M screen), the menu of "T/M Trigger Learning Data Reset" is highlighted. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return to the Adjustment Menu screen for menu selection. 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 (4) T/M screen

1] Adjustment (load meter) When this screen (Adjustment Menu (1) Load Meter screen) is displayed first, the menu of "Boom Ang. Sensor (Upr) (Eqp Ctrl) Adj." is highlighted. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return to the Adjustment Menu screen for menu selection. 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 (1) Load Meter screen

Press [F1] to return to the Adjustment 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"

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Boom Angle Sensor (Upper) Adjustment screen

Press [F1] to return the Adjustment 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" Boom Angle Sensor (Lower) Adjustment screen

If the current set value cannot be received 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 sent from the main monitor (while "---" is displayed). The numeric value must not exceed the upper and lower limits of setting range. q Numeric value setting range Metric ton: 20 to 99 [t] 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 raised irrespective of the payload. q When the unit setting is switched between metric ton and US ton, the record previous set value is reduced to that in the specified unit and is displayed on the screen. (example) If you set the payload 20 [t] in metric ton 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

When this screen (Payload Setting screen) is switched from the standard screen, the current set value of payload is displayed. The current set value is displayed according to the information from the main monitor. "---" is indicated for the set value until the value is sent from the main monitor.

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 Adjustment Menu (1) Load Meter screen. When the multi-function monitor cannot receive the reception notice from the main monitor for 10 seconds or more after informing the main monitor of the accepted set value, the screen switches to the abort screen. Note that the switch operation is not accepted until the current set value is sent from the main monitor (while "---" is displayed).

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Press [F1] to cancel the setting and return to the Adjustment Menu (1) Load Meter screen. Payload Setting screen

[*1]: The title displays the setting item. 2] Adjustment (AJSS) When this screen (Adjustment Menu (2) AJSS screen) is displayed, the menu of "AJSS Neutral Position Adjustment" is highlighted. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4]to highlight the upper menu. If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return to the Adjustment Menu screen for menu selection. 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 (2) AJSS screen

As for the triangle marksE and E that appear above and below the figure respectively, when the figure is lower limit of the range, onlyR appears. When the figure is upper limit of the range, only Rappears. The main monitor issues the command to the multi monitor to switch to this screen when aborted. After the transition, the multi monitor (KOMTRAX Plus) performs the processing. After reading the message, press [F5] to move to the Adjustment Menu (1) Load Meter screen. When the communication error with the controller continues for 0.5 second or more during the adjustment, the screen returns to Service Menu screen without going through the abort screen. Abort confirmation screen of load meter relevant setting

Press [F1] to return to the Adjustment Menu (2) AJSS screen. Press [F6] to send the set signal to the work equipment controller. The message below appears according to the command (setting completion or wrong setting) from the work equipment controller. When setting is completed: "Setting Completed" When setting is not completed: "Wrong Setting" Until receiving a command: "In setting"

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AJSS Neutral Position Adjustment screen

AJSS EPC Output Current Adjustment screen

When this screen is displayed first, the adjustment current value is displayed according to the information from the work equipment controller. "---" is indicated for the value until the information is sent from the work equipment controller first. Press [F1] to move back to the Adjustment Menu (2) AJSS screen. Press [F3] to send the DOWN signal to the work equipment controller. After the transmission, the multi-function monitor updates the adjustment current value 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 operations of the multi-function monitor are required for the numeric value change. Press [F4] to send the UP signal to the work equipment controller. After the transmission, the multi-function monitor updates the adjustment current value 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 operations of the multi-function monitor are required for the numeric value change.

a As for the triangle marks E and R that appear above and below the figure respectively, when the figure is lower limit of the range, only E appears. When the figure is upper limit of the range, only R appears. When this screen is displayed first, the table pattern number is displayed according to the information from the work equipment controller. "" is displayed for the number until the information is received first after the screen transition. Press [F1] to return to the Adjustment Menu (2) AJSS screen. Press [F6] to send the change signal of the AJSS oil pressure command table pattern to the work equipment 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 operations of the multi-function monitor are required for the numeric value change.

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AJSS oil pressure command table pattern change screen

Press [F4] to highlight the upper menu. (Scroll function) If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return the Adjustment Menu screen for menu selection. 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 (3) Work Equipment screen

The main monitor issues the command to the multi-function monitor move to this screen when aborted. After the transition, the multi monitor (KOMTRAX Plus) performs the processing. After reading the message, press [F5] to switch to the Adjustment Menu (2) AJSS screen. When the communication error with the controller continues for 0.5 seconds or more during the adjustment, the screen returns to the Service Menu screen without going through the abort screen. Abort confirmation screen of AJSS relevant setting

3] Adjustment (work equipment) When this screen (Adjustment Menu (3) Work Equipment screen) is displayed first, the menu of "Boom Ang. Sensor (Upr) (Eqp Ctr) Adj." is highlighted. Press [F3] to highlight the lower menu. (Scroll function) If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu.

Press [F1] to return the Adjustment Menu (3) Work Equipment screen. Press [F6] to send the set signal to the work equipment controller. The message below appears according to the command (setting completion or wrong setting) from the work equipment controller. When setting is completed: "Setting Completed" When setting is not completed: "Wrong Setting" Until receiving a command: "In setting"

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Boom Ang. Sensor (Upr) (Eqp Ctr) Adj. screen

Press [F1] to move back to the Adjustment Menu (3) Work Equipment screen. Press [F6] to send the set signal to the work equipment controller. The message below appears according to the command (setting completion or wrong setting) from the work equipment controller. When setting is completed: "Setting Completed" When setting is not completed: "Wrong Setting" Until receiving a command: "In setting" [Special notes] This screen provides two types of adjustments and the work equipment controller selects the adjustment based on the 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 boom raise lever & EPC

Press [F1] to return to the Adjustment Menu (3) Work Equipment screen. Press [F6] to send the set signal to the work equipment controller. The message below appears according to the command (setting completion or wrong setting) from the work equipment controller. When setting is completed: "Setting Completed" When setting is not completed: "Wrong Setting" Until receiving a command: "In setting" [Special notes] This screen provides two types of adjustments and the work equipment controller selects the adjustment based on the engine speed. (The multi monitor is not involved in it.) Adjustment item q Adjusting lift arm lever LOWER detent position q Adjusting boom LOWER EPC current Dead zone variation adjustment screen of boom lower lever & EPC

Press [F1] to return to the Adjustment Menu (3) Work Equipment screen. Press [F6] to send the set signal to the work equipment controller. The message below appears according to the command (setting completion or wrong setting) from the work equipment controller. When setting is completed: "Setting Completed" When setting is not completed: "Wrong Setting" Until receiving a command: "In setting" [Special notes] This screen provides two types of adjustments and the work equipment controller selects the adjustment based on the engine speed. WA1200-6

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(The multi monitor is not involved in it.) Adjustment item q Adjusting bucket TILT detent position q Adjusting bucket TILT EPC current Dead zone variation adjustment screen of bucket tilt lever & EPC

Press [F1] to return to the Adjustment Menu (3) Work Equipment screen. Press [F6] to send the set signal to the work equipment controller. The message below appears according to the command (setting completion or wrong setting) from the work equipment controller. When setting is completed: "Setting Completed" When setting is not completed: "Wrong Setting" Until receiving a command: "In 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

When this screen is displayed first, the table pattern number is displayed according to the information from the work equipment controller. "" is displayed for the number until the information is received first after the screen transition. Press [F1] to return to the Adjustment Menu (3) Work Equipment screen. Press [F6] to send the change signal of the boom lever pattern to the work equipment 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 operations of the multi-function monitor are required for the numeric value change. Boom Lever Pattern Change screen

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When this screen is displayed first, the table pattern number is displayed according to the information from the work equipment controller. "" is displayed for the number until the information is received first after the screen transition. Press [F1] to return to the Adjustment Menu (3) Work Equipment screen. Press [F6] to send the change signal of the bucket lever pattern to the work equipment 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 operations of the multi-function monitor are required for the numeric value change. Bucket Lever Pattern Change screen

Press [F4] to send the UP signal to the work equipment controller. After the transmission, the multi-function monitor updates the numeric value (%) 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 operations of the multi-function monitor are required for the numeric value change. Boom Lower Stop Modulation Adj. screen

a As for the triangle marks E and R that appear above and below the figure respectively, when the figure is lower limit of the range, only E appears. When the figure is upper limit of the range, only R appears. The main monitor issues the command to the multi-function monitor to move to this screen when aborted. After the transition, the multi-function monitor (KOMTRAX Plus) performs the processing. After reading the message, press [F5] to move to the Adjustment Menu (3) Work Equipment screen. When the communication error with the controller continues for 0.5 second or more during the adjustment, the screen returns to Service Menu screen without going through the abort screen.

When this screen is displayed first, the table pattern number is displayed according to the information from the work equipment controller. " -" is displayed for the value until the information is received first after the screen transition. Press [F1] to return to the Adjustment Menu (3) Work Equipment screen. Press [F3] to send the DOWN signal to the work equipment controller. After the transmission, the multi-function monitor updates the adjustment current value 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 operations of the multi-function monitor are required for the numeric value change.

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Abort confirmation screen of work equipment relevant setting

Adjustment Menu (4) T/M screen

[*]: The title displays the setting item. 4] Adjustment (transmission controller) When this screen (Adjustment Menu (4) T/M screen) is displayed first, the menu of "T/M Trigger Learning Data Reset" is highlighted. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. Press [F4] to highlight the upper menu. If the uppermost menu is highlighted, pressing [F4] highlights the lowermost menu. Press [F1] to return to the Adjustment Menu screen for menu selection. Press [F6] to move to the execution screen for the menu highlighted at present. (For more information, refer to the description of the screen.)

Press [F2] to return to the Adjustment Menu (4) T/M screen. Press [F5] to send the reset signal to the transmission controller and move to the setting completion screen. Use the real time monitor function to check whether the data is reset. T/M Trigger Learning Data Reset screen

Press [F1] to return to the Adjustment Menu (4) T/M screen. The message below appears according to the command (setting completion or wrong setting) from the transmission controller. When setting is completed: "Setting Completed" When setting is not completed: "Wrong Setting" Until receiving a command: "In setting"

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T/M Trigger Learning Data Reset screen (setting completion screen)

The main monitor issues the command to the multi-function monitor to move to this screen when aborted. After the transition, the multi-function monitor (KOMTRAX Plus) performs the processing. After reading the message, press [F5] to move to the Adjustment Menu (4) T/M screen. When the communication error with the controller continues for 0.5 second or more during the adjustment, the screen returns to the Service Menu screen without going through the abort screen. Abort confirmation screen of transmission relevant setting

6) Option setting When this screen (Option Setting screen) is displayed first, the menu of "boom Specification" 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 screen for menu selection. Press [F6] to change the option setting of the item highlighted at present. (If the setting is changed, the change is sent through the network.) The main monitor also saves all option settings so that it can detect disagreement between the option settings and actual machine conditions. Press [F2] to move to the next page of the Option Setting screen. Option Setting screen (1/2)

Option Setting screen (2/2)

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Default Boom specification Tire type Tire size correction Economy operation indication lamp 3rd gear prophibition Wall digging prophibition Tire slip prevention control Dump truck approach control Travel speed control AT the over load boom rise stop control Default STD STD 0% ADD NO ADD ADD ADD ADD TYPE 1 NO ADD Option Hi Lift Ext Hi Lift OPT1 OPT2 12% (in increments of 2 %) (*1) NO ADD ADD NO ADD NO ADD NO ADD TYPE 2 ADD

Maintenance remaining time screen (page 1)

Fixed to Engine mode AUTO Fixed to E P To display the engine mode screen, you must enter the special ID when entering the service ID. (*1) The value changes in following order: +0o+2o+4oo+12o-2o-4oo-12o+0

* The maintenance monitor screen has four pages. For information on other pages, refer to "2-4) Maintenance monitor" in the user menu. When this screen is displayed, numeral "1" is displayed. Press [F1] to revert the change interval back to the one before moving to this screen and return to the previous screen. Press [F2] delete a numeral entered last. If no numeral is entered, the screen does not change. Press [F3] to highlight a numeral on the left of the numeral selected (highlighted) at present. If the numeral highlighted at present is "1", pressing [F3] highlights "0". Press [F4] to highlight a numeral on the right of the numeral selected (highlighted) at present. If the numeral highlighted at present is "0", 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 accept the current change interval displayed in the entry field and return to the previous screen. 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 maintenance 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.

7) Maintenance monitor (for service) The remaining time to next maintenance is displayed on the maintenance monitor screen. Press [F1] to return to the Service Menu screen. Press [F5] to move to the next page. If page 4 is displayed, pressing [F5] displays page 1. Press [F2] to move to the previous page. If page 1 is displayed, pressing [F2] displays page 4. Press [F3] to highlight the lower menu. If the lowermost menu is highlighted, pressing [F3] highlights the uppermost menu. 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 interval change screen for the menu item highlighted at present.

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Maintenance interval change screen

Unit Setting screen

8) Unit selection Use this screen to select the unit system of numeric values displayed on the multi-function monitor screen. The unit set in this screen has an impact on the travel speed unit in the main monitor and the unit of the load meter. When "ENGLISH" is selected as a unit system, the travel speed unit in the main monitor changes to "MPH" and the display unit of the load meter changes to "short ton". When other unit system is selected, the travel speed unit and the display unit of the load meter remain "km/h" and "metric ton" respectively. When this screen is displayed first, the current unit system is highlighted. Press [F1] to return to the Service Menu screen. Press [F3] to change the highlighted unit system in order of METRICoENGLISHoSIo METRIC. Press [F4] to change the highlighted unit system in order of METRICoSIoENGLISHo METRIC. Press [F6] to accept the current unit system highlighted and return to the Service Menu screen.

9) Deleting memory When this screen is displayed, numeral "1" is displayed. Press [F1] to return to the Service Menu screen. Press [F2] delete a numeral entered last. If no numeral is entered, the screen does not change. Press [F3] to highlight a numeral on the left of the numeral selected (highlighted) at present. If the numeral highlighted at present is "1", pressing [F3] highlights "0". Press [F4] to highlight a numeral on the right of the numeral selected (highlighted) at present. If the numeral highlighted at present is "0", pressing [F4] highlights "1" Press [F5] to select the numeral highlighted at present and display "*" in the entry field (input from the upper digit). Press [F6] to accept the current ID displayed. When it is correct ID, the screen switches to the MEMORY CLEAR screen. When it is a wrong ID, the screen remains unchanged. However, the text changes to "Enter a correct ID." and the wrong ID is deleted from the entry field. When a correct ID is entered, the screen switches the MEMORY CLEAR screen. Or, press [F1] to return to the Service Menu screen.

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Service ID input screen

MEMORY CLEAR confirmation screen

When this screen is displayed first, the menu of "Failure History Data" is highlighted. Press [F1] to return to the Service Menu screen. 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 [F6] to move to the MEMORY CLEAR confirmation screen of the menu item highlighted at present. MEMORY CLEAR screen

a The item name selected appears in "*****". q Failure History data, Maintenance Data, Trend Data, Load Map Data, Snap Shot Data 10) Serial/GCC number setting This screen displays the current settings. Press [F1] to return to the Service Menu screen. Serial/GCC No. Setting 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.

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Multi-function monitor

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Work equipment and AJSS control system

*AJSS: Advanced joystick steering system Electrical circuit diagram of work equipment and AJSS control

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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 operating the work equipment.

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The work equipment lever is equipped with detent notches and both the lift arm and bucket are controlled 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.

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2. Work equipment neutral lock Function q When the work equipment lock lever is set to the LOCK position, the work equipment lock switch becomes 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 equipment is locked.

When the work equipment lock lever is in LOCK position, moving the work equipment lever to a operation position and setting the lock lever to FREE position does not cancel the work equipment lock condition. This safety function keeps work equipment lock condition until all the work equipment control are returned to neutral.
Input to controller Operation of work equipment Work equipment lever potentiometer Work equipment lever in operating position Work equipment lock is released and then all control are returned to neutral Output from controller Work equipment neutral lock valve ON (24 V) ON (24 V) OFF (OPEN) OFF (OPEN) Operation of machine Oil pressure Cut Cut

Operation table Operation by man

Work equipment lock Work equipment lock lever lever switch Low position OFF (LOCK) (OPEN) Low oHigh position OFF (unlocking) (OPEN) Low oHigh position (unlocking) High position (FREE) OFF (OPEN) ON (CLOSE)

Operative

Operative

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Flowchart

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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 controller. 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".

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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

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3) Operation when the lever is moved from acceleration to deceleration control a Determination of acceleration and deceleration 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 current value (current value determined from the target flow rate) + Hysteresis current value When the lever is in deceleration control q Output current value = Command current value (current value determined from the target flow rate) When the lever is in hold control q The previous output current value is maintained.

5) Operation when the lever is held at a certain position

4) Operation when the lever is moved from deceleration to acceleration control

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6) During calibration of lever and EPC a This control is not applied during the calibration. 7) Trigger table
Lift arm RAISE Trigger time Trigger current Hysteresis time
q

Lift arm LOWER 0.0 sec 800 mA 0 mA

Bucket TILT 0.0 sec 800 mA 0 mA

Bucket DUMP 0.0 sec 800 mA 0 mA

0.0 sec 800 mA 0 mA

Permission flag of trigger output current. (Mask bit is used for the first increment of time.) Trigger output current is allowed to flow when the controller recognizes that the lever is in the neutral position for 1 second or more. a Trigger current is not produced while the lever is rapidly moved.

5. Lift arm stop modulation Function q When the operator performs lift arm RAISE or LOWER stop operation more quickly than a certain speed, the work equipment controller starts the modulating function to prevent lift arm stop shock. q The operation of this "stop modulation function" can be adjusted by changing the setting of the controller. a For the procedure and precautions of changing the modulation setting, see Testing and adjusting, "Change of stop modulation at lift arm RAISE/LOWER".

1) Stop modulation for lift arm LOWER Equivalent of the valve slow return function q The lift arm LOWER stop speed can be changed by adjusting the deceleration flow rate for the stop modulation using the calibration function. The modulation does not function if the flow rate at the start of deceleration is 30% or more of the target flow rate. a For the deceleration flow rate, see 3) Table (set value). : The default of calibration set value is 100 %. 2) Stop modulation for lift arm RAISE Equivalent of the valve slow return function q The lift arm RAISE stop speed can be changed by adjusting the deceleration flow rate for the stop modulation using the calibration function. The modulation does not function if the flow rate at the start of deceleration is 30 % or more of the target flow rate. a For the deceleration flow rate, see 3) Table (set value). : The default of calibration set value is 100 %. 3) Table (set value)
Deceleration flow rate Operation 0% 100 % 200 % Flow rate at deceleration start Less than 30 % of target flow rate Less than 30 % of target flow rate

RAISE

0.75 %/msec

0.5 %/msec

0.05 %/msec

LOWER

1.05 %/msec

0.7 %/msec

0.15 %/msec

a Note that the modulation does not function when the deceleration flow rate is 0 %.

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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.

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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%.

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Bucket positioner control 10-289 Functions q The controller constantly detects operating direction of the lever from the bucket control lever potentiometer 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

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Lift arm remote positioner

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1. Function q The lift arm remote positioner functions to slow the lift arm to a halt in RAISE and LOWER operations. a The controller keeps detecting the operating direction of the lift arm control lever from its potentiometer and the angle (position) of the lift arm from its angle potentiometer. 1) RAISE kick-out (with RAISE lamp ON) q When the lift arm control lever is moved to the "raise detent" position, the lift arm starts to slow at a position 9 deg. short of the set position, and the raise detent is released at a position 2 deg. short of the set position to provide lift arm stop modulation control. q The lift arm is raised by the operator except when it is in the "raise detent" position. * The raise detent only functions when the remote positioner raise stop mode is not selected. * The remote positoner does not function if the lever is in the detent position, and the kick-out function only (stopping the lift arm at TOP) is activated.

2) Lower lift arm stop (with lower lamp ON) q When the lift arm control lever is moved to the "float detent" position, the lift arm starts to slow at a position 9 deg. short of the set position, and the float detent is released at a position 2 deg. short of the set position to provide lift arm stop modulation control. q The lift arm starts to go down again if the lift arm control lever is held at the position. * The float detent only functions when the remote positioner lower stop mode is not selected. * The remote positoner does not function if the lever is in the detent position with the lift arm angle below the horizontal position, and the float detent function (no automatic halt) only is activated.

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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.

Selec tion Raise selection Lowe r selection

Selection mode Raise stop ON(q) Lower stop OFF(Q) Raise/Lower stop ON(q)

Raise Min. 0 deg.

Stop position Lower (*1) 0-37 deg.

Lower (*2) 0-33 deg.

OFF(Q)

ON(q)

ON(q)

0 deg.: Lift arm horizontal position (Default for both raise and lower) (*1): STD lift arm (*2): Hi Lift lift arm a The calibration of the raise position is performed 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 positioner stop position (Available setting range of raise/lower stop position)

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2) Input/output

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3) Control details 1] Raise position setting

1 Remote positioner raise See 1. 1). stop control Availability 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 sensor 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 positioner 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 depression, 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

1 Remote positioner lower See 1. 2). stop control Availability 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 positioner 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 depression, 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.)

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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.
Output conditions The lift arm angle is within the setting range when the remote positioner is not selected and the position set switch is set to ON. The lift arm angle is out of the setting range when the remote positioner is not selected and the position set switch is set to ON. The lift arm angle is out of the setting range when the remote positioner is selected and the position set switch is reset to ON. Selection switch built-in indicator ON Buzzer sound output Stop position The set completion Controlled by the saved buzzer sounds when the value at the time of the set switch is pressed. switch depression Not controlled. Off None in particular Raise/Float detent is controlled. Controlled by the previously saved value. ON None in particular The saved value is unchanged. Not controlled. The saved value is Off No (Error buzzer sounds) unchanged. Raise/Float detent is controlled. Not controlled. No (Error is displayed on Raise/Float detent is Off the multi monitor.) controlled. The set completion Controlled by the saved ON buzzer sounds when the value at the time of the set switch is pressed. switch depression The indicator turns The indicator turns off Not controlled. off after a lapse of 1 after a lapse of 1 second Raise/Float detent is second with the set with the set switch controlled. switch pressed. pressed.

In case of sensor abnormality

In case of set switch abnormality The lift arm angle is within the setting range when the remote positioner is selected and the position set switch is reset to ON. When the remote positioner function is not selected (When resetting is made with the switch pressed for 1 second or more)

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.

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5. Lift arm detent control 1) ON/OFF conditions of lift arm raise detent solenoid 1] In the raise stop mode
Lever stroke (st) st > 60 st < 60 Lift arm detent Raise solenoid angle output Area A in the figON ure Area B in the figOFF ure

2) ON/OFF conditions of lift arm float detent solenoid 1] In the lower stop mode
Lever stroke (st) st < -60 -60 > st Lift arm detent angle Area C in the figure Area D in the figure Float solenoid output ON OFF

2] When the lower stop mode or remote positioner is not selected a See "3) Lift arm kick-out function".

2] When the raise stop mode or remote positioner is not selected a See "4) Lift arm float function".

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3) Lift arm kick-out function ON/OFF conditions of lift arm raise detent solenoid
Lever stroke (st) st > 60 st < 60 Lift arm detent angle Area A in the figure Area B in the figure Raise solenoid output ON OFF

a When the kick-out function is activated, the target stop angle is regarded as "-** deg. in the table" to the maximum lift arm angle of each lift arm specification.
STD Hi Lift Extra Hi Lift -5.0 deg -5.0 deg -5.0 deg

4) Lift arm float function ON/OFF conditions of lift arm float detent solenoid
Lever stroke (st) Above NEUTRAL -60<st LOWER St<-60 Float solenoid output ON OFF

5) Detent actuation with engine stopped q Detent solenoid remains OFF when the engine is stopped. q The engine shutdown is determined as follows.

(*) : 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 positioner raise stop function q The detent solenoid on the reverse side (the lower detent solenoid for the cancellation of the raise detent function) is set to OFF for 1 second after the detent function is canceled by the lower stop function.

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6. Lift arm raise stop modulation control 1) Command flow rate for deceleration of lift arm raise
Toward raise side from Stop angle stop angle 100 100 40 15 10 0 Toward lower side from stop angle 45 -2 50 -4 100 -9 100 -15

Target flow rate (%) Lift arm angle ()

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 modulation 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 rate 0.2%/msec

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Start angle of raise stop modulation (deg.) 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 TOP(32.8 deg.49.47 deg. 1.5 ) 25 deg.(16.4 deg.32.8 de Lift arm stop angle 1.0 g.) Horizontal 1.0 (0 deg.-16.4 deg.) I Set position (set angle) 15054 1.0 1.0 1.0 7527 0.4 0.4 0.4 3764 0.2 0.2 0.2

7. Lift arm lower stop control

Conditions Case A B C D E Above a level in angle Start position of lift arm lowering Below a level in angle When detent is canceled Lift arm position Control details Modulation at the Lift arm decelertime of detent ation control cancellation x(*1) x(*1) Q x x(*2)

Automatic can(Outside the limitation x cellation Manual holding range of deceleration) Automatic can[Bucket placed horiQ cellation zontally on the ground] Manual holding Below the limitation Above the decelManual holding angle of eration limitation 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.

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a The set angle of the limitation range of lift arm lower stop deceleration depends on the lift arm specifications.
STD Hi Lift Extra Hi Lift -37 deg -33 deg

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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 from stop angle 100 100 -15 -10 Stop angle 35 0 Toward raise side from stop angle 35 2 40 3 50 4 100 7 100 10

Target flow rate (%) Lift arm angle ()

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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 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 modulation 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 limitation 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 from stop angle 100 100 -15 -10 Stop angle 35 0 Toward raise side from stop angle 35 2 40 3 50 4 100 7 100 10

Target flow rate (%) Lift arm angle ()

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 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%.)

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10-302 Control of semi auto-digging 1. Function q Semi auto-digging control allows the operator to perform automate bucket operation while raising the lift arm. In this mode, the lift arm operating stroke, engine speed, and lift arm angle are detected and used to control the bucket EPC.

This function allows even inexperienced operators to perform more efficient operation. Two material modes, "Loose/Soft mode" and "Rock/Hard mode", are available in this semi-auto digging. Select an appropriate mode to perform automatic bucket operation that matches the characteristics of the material. Mode selection
Object Gravel/sand Quarry/blasted rock Mode Loose/Soft mode Rock/Hard mode

No 1 2

2. System configuration

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3. Control method q Highly responsive open-loop control for bucket operation without using feedback q Operator intervention is allowed.

NC control

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PNC control

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Function q NC control serves to set the swash plate angle of the work equipment pumps to the minimum when no work equipment is operated so that fuel consumption is reduced. 1. ON/OFF conditions of NC control q When operation command is generated for the bucket or lift arm: OFF q Cases other than above: ON 2. Processes when NC control is set to ON/OFF ON : NC solenoid is energized (the swash plates of the work equipment pump 1 and 2 are at minimum angle). OFF : NC solenoid is de-energized (the swash plates of the work equipment pump 1 and 2 are at maximum).

Function q PNC control serves to set the swash plate angle of the switch pump when the work equipment is in operation so that sufficient oil flow is provided to the work equipment. 1. ON/OFF conditions of PNC control q When operation command is generated for the bucket or lift arm with (hysteresis ON): ON q Cases other than above: OFF Hysteresis q Default: Hysteresis = ON q The hysteresis is set to OFF if work equipment pump pressure becomes > 29.4 MPa {300 kg/cm2} with hysteresis ON 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.

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AJSS control

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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 articulation 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 angle 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 operation 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.

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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 transmission controller. Therefore, if the forward-reverse switch of the joystick steering knob is set to a position 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.

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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".

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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. (Automatic 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)

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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

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Input/output signal
[CN-L05][DEUTSCH-24P] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name Bucket lever potentio B Looder pump press. sensor AJSS frame potentio GND_SIG_D NC NC Bucket lever potentio A Boom angle sensor AJSS lever poteinto GND_SIG_D NC NC Input and output signals Input Input Input Input Input Input Input Input Input Input Input and outPin No. Signal name put signals 13 Boom lever potentio B Input 14 Boom bottom press sensor Input 15 NC Input 16 NC Output 17 Semiauto looding loose mode SW. Input 18 NC Input 19 Boom lever potentio A Input 20 NC Input 21 GND_SIG_A 22 PWR_OUT_5V_0 Output 23 Semiauto looding rock mode SW. Input 24 NC Input

[CN-L06]DEUTSCH-40P(1) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 NC Winker SW. right Remots positioner levering set SW. NC NC Active power up solenoid signal NC Winker relay left Loader pump solenoid relay NC NC NC Remote positioner lifting set SW. NC NC Pnc solenoid 2 signal NC Winker relay right Sw pump PNC soienoid relay NC Input Output Input Input Input Output Output Input Signal name Input and output signals Output Input Input Input Input Input Input Output Output Input Output Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 NC COMM_CAN_L_O NC PWR_CTR_EXT Starter switch(IGN-C) Pnc solenoid 1 signal NC NC NC NC NC COMM_CAN_H_O NC NC lever pronibiting equipment SW. NC NC Winker SW. left NC NC Signal name Input and output signals Input/out put Input/out put Input/out put Input Input Input Input Input Input Input/out put Input/out put Input Input Input Input Input

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[CN-L07]DEUTSCH-40P(2) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name PWR_IN_BATT PWR_IN_BRY GND_ACT Safety relay Bucket tilting EPC Boom lifting EPC Work neutral lock solenoid Remote positioner lifting lndicator NC Bucket cylinder tilt end SW. PWR_IN_BATT PWR_IN_BRY GND_ACT PWR_CTR_KEY Bucket dumping EPC Boom lowering EPC Magnetic detent of boom lever lift Remote positioner lovering indicator NC Bucket cylinder horizon SW. Input and output signals Input Input Output Output Output Output Output Input Input Input Input Input Output Output Output Output Input Input Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name GND_PWR PWR_IN_BRY GND_ACT PWR_CTR_KEY Bucket tilting EPC 2 AJSS EPC Magnetic detent of boom lever float Boom lifting EPC 1 NC (Tilt limiter ON/OFF (If equipped)) NC GND_PWR GND_PWR GND_PWR NC Bucket dumping EPC 2 NC SOL Magnetic detent of bucket lever tilt Boom lowering EPC 1 Loader pump swash plate cotrol cacsel SW. NC Input and output signals Input Input Output Output Output Output Input Input

Output Output Output Output Output Input Input

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Electrical system Work equipment control lever

Work equipment control lever

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1. Lever 2. Rod 3. Centering spring 4. Metering spring 5. Nut 6. Rod 7. Detent spring 8. Retainer 9. Lever 10. Potentiometer

11. Seat 12. Ball 13. Detent spring 14. Rod 15. Body 16. Solenoid 17. Bushing 18. Body 19. Retainer 20. Rod

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Electrical system Work equipment control lever

10-314 Function 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 output.
q

10-314 Operation 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 potentiometer (10) is coupled with rod (14). q Potentiometer (10) outputs the signal voltage according to the vertical stroke amount of rod. When operation lever "Lift arm Lower" is operat10-314 ed (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) q When rods (2), (14) are pushed further, ball (12) pushes upward retainer (8) supported by detent spring (7) and goes outside to travel over protruding portion (a) of rod (14). q Opposite rod (20) is pushed upward by spring (4). q When rod (20) is pushed upward while solenoid (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.

When operation lever "Lift arm Lower" is re10-314 leased q To release "Lift arm Lower" position of lever (1), push down rod (20) with the force over the suction force of solenoid suction. Or, when the solenoid power is turned off, "Lift arm Lower" position is released and lever (1) returns to neutral position.

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Transmission control system

System overview
Auto shift Modulation control Kickdown function Safety function Manual shift Modulation control Kickdown function Safety function Traveling control function (forward/reverse, shifting range)

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Self-diagnosis function Status display (output, failure code) Failure diagnosis (system error, disconnection to system, detection of short-circuit) Communication function

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. 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. 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. 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. 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.

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Electrical circuit diagram of transmission controller

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Function 1. Auto shift function Shift-up and shift-down of the transmission are controlled by the signals from travel direction, gear range, and the travel speed sensor, according to Contents of control by transmission controller 1. Normal automatic shifting and gear-shifting prohibition time table which is stored in the transmission controller memory. 1) Shifting range (1st to 3rd) The maximum gear speed (gear shifting range) in the automatic gear shift mode is limited. Example: Gear shift lever at 3: Between 2nd and 3rd speed Gear shift lever at 2: 2nd speed only Gear shift lever at 1: 1st speed only 2) Directional selector switch "N" position At the neutral position, only the speed clutch of the transmission is operated. 3) Directional selector switch "F" position When the directional selector switch is set from N to F, the ECMV of F clutch on the transmission is energized. When the shift lever is positioned at 2 or 3, the machine starts at the 2nd speed. a) Upshifting (when the gear shift lever is at 3) When the accelerator pedal is depressed to increase the travel speed to approximately 9.7 km/h, the 3rd gear of ECMV is turned ON and the 2nd gear is turned OFF. (Gear is shifted to F3) 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 approximately 1 km/h, the transmission is shifted to the 2nd gear.

10-320 4) Directional selector switch "R" position In the same way in position F, the transmission is shifted automatically between the 2nd and 3rd (when the gear shift range is 3), according to the travel speed. 5) Skip shift If the accelerator pedal is depressed while the machine is coasting in 3rd gear at speed below 8.3 km/h, the transmission is shifted to 2nd gear immediately so that the machine can be accelerated easily. 6) Disapproved shift time To prevent shift hunting after shifting, the time to maintain the gear speed is provided. The non-shifting time varies depending on the shifting pattern. Refer to the "Transmission controller details 1. List of normal automatic shifting and non-shifting time". 2. Modulation control To reduce shock in gear shifting (clutch engagement shock), the controller controls ON/OFF of all clutches according to the data memorized in the transmission controller so that optimum clutch pressure (including buid-up characteristics) is obtained depending on the hydraulic circuit conditions such as the engine speed, transmission oil temperature and shifting pattern. To reduce torque interruption, this modulation control is applied to the ECMV of the clutch that is disengaged.

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3. Kickdown function This function allows the operator to shift the gear speed to F1 forcibly by simply pressing the kick-down switch if conditions for kick-down (traveling mode, gear speed and travel speed) are satisfied. 1) Auto shift mode When the travel speed is less than 13 km/h during traveling forward or in reverse, kickdown function is effective. It is also effective while the machine is in the gear speed hold mode (auto shift OFF mode). The kick-down is canceled and gear speed shift to 2nd when the travel speed is increased or travel direction is switched between forward/reverse. 2) Manual shift mode Kickdown is effective during traveling forward at the 2nd gear speed. The kick-down is canceled and gear speed shift to 2nd when the upshift/downshift switch is pressed or travel direction is switched between forward/reverse. 4. Traveling mode The traveling mode switch can change the mode between auto and manual shift. In manual mode, shifting is performed with the upshift/downshift switch. 5. Safety function 1) Transmission neutralizer function When the steering lock lever is ON (locked) or the machine is in stop before start of the engine, this sets the transmission to the neutral position. This function sets the transmission in neutral when the steering lock lever is set to LOCL (locked) or the machine is in stop before start of the engine. 2) Neutral safety When the directional selector switch is not at 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 downshifting 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.

5) Manual shift If the travel speed data cannot be detected due to error of the travel speed sensor, the machine enters manual (shift) mode. 6. Self-diagnosis function The transmission controller always monitors the input/output signals of the travel control system and performs self-diganosis. With the real time monitoring function of the multi monitor, the status of the controller input/output signal can be checked. a For the displayed items, see "Multi monitor", "3. Service menu, 1) Real-time monitor". 7. Communication function The transmission has a communication function with CAN and receives tire correction data etc. from the multi monitor. If a signal error occurs in the transmission control system, the controller generates the action code that depends on the seriousness of the failure and sends it to the multi monitor. The multi monitor displays it on the screen to warn the operator for safe operation. The failure code generated are recorded in the multi monitor, they can be checked by using with the failure history menu of the multi monitor. 8. Transmission controller power supply When the starting switch is turned to ON position and the supply voltage is 20 V or more, and when power supply input of the transmission controller solenoids is the 18 V or more, the controller can drive the solenoids. If the power supply voltage decreases to 18 V or below, all outputs are turned OFF and no control is made. The recovery condition is that the supply voltage is 20 V or more. The neutral safety function is activated to enable traveling.

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Transmission controller details 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 2080 80100 0 20 2080 80100 0 20 2080 80100 (+) side pulse count X5 589 589 589 1,689 1,689 1,689 5.6 5.6 5.6 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 sig957 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 sig908 908 908 749 749 749 8.7 8.7 8.7 nal 3rdo2nd ON (1,450 rpm or more) Modulation clutch output shaft speed signal 109 109 109 90 90 90 1.0 1.0 1.0 OFF (less than 1,450 rpm) Modulation clutch output 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

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Shift-down

Shift-up

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 [sec] 2.00

Gear shifting Shift-up 1sto2nd

Applicable conditions

2ndo3rd

Modulation clutch out-put shaft speed signal ON (1,450 rpm or more) Modulation clutch output shaft speed signal OFF (less than 1,450 rpm) Modulation clutch output shaft speed signal OFF (less than 1,450 rpm) oON (1,450 rpm or more)

2.00

2.00

Shift-down

3rdo2nd

0.00

2.00

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3) Auto shift operation table

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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 Shifting range display Not shifted. Actual gear speed 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
Actual gear speed Shifting range display Gear speed corresponding to the travel speed (evaluated by the upshift point of automatic transmission). 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 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.) (1) Start-up

2] Shifting range display

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

(5) In AJSS auto shift

3] Traveling mode (auto shift/manual) q Depends on the input signal.

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3. Solenoid output when FNR is changed Monitor the FNR signal full time. This supersedes other controls.
AJSS knob switch F N R F Q Manual mode solenoid output R Gear speed before N Q Q AJSS knob switch F N R Auto shift mode solenoid output F R 2nd speed (*) Q Q 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

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2) Auto shift pattern q The upshift/downshift switch functions as the shifting range selector.

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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

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. 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 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. 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.

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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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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 downshift 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 protection 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 implementation.

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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 corresponding to the travel speed (according to the shifting point in Fig. 1). Then, downshift is performed 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 longer. <Example> When the speed position switch is at the 1st speed, F1, shifting of 14 km/hoR is performed Shifting of F1oR3oR2oR1 is performed.

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Electrical system Transmission control system

2] In manual mode (speed position switch before shifting is the 2nd or 3rd) Fig. 2

2)

3)

4) 5)

(*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 shifting point in Fig. 2). Then, downshift is performed to the speed position corresponding to the travel 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 longer. Inhibition time setting q Set the inhibition time after directional change (from start of shifting). Do not change the speed during 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. 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. 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. 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).

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10-3 2 Engine control 1. Engine throttle control q For the engine control, the transmission controller sends the lower limit of throttle position to the engine controller through the NET communication. The engine controller uses the value to control the engine. q The priority of signals used for the engine control by the engine controller is as follows: a) Throttle lower limit V b) Input signal value from throttle pedal (Detected by engine controller) 2. Throttle signal output value setting q The throttle signal value sent to the engine controller is expressed in by the throttle lower limit. q The throttle lower limit is set by the throttle lock function. q If the throttle lower limit value is not set by the throttle lock function, the value is set to 0 % which is the default value. 3. Throttle lock function 1) Outline 1] The throttle lock function switch is the alternate switch of 3 positions. When the upper part is pressed, the throttle lock is activated without auto deceleration. When the lower part is pressed, the throttle lock is activated with auto deceleration. At the neutral position, the throttle lock function is disabled. 2] Press the upper part or lower part (activated) of the throttle lock function and depress the acclerator pedal. When the desired engine speed is reached, press the throttle lock SET/ACCEL switch to set the throttle level. 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

6] The throttle level once set can be cleared with the conditions below. q Set the throttle lock function switch to the OFF position. or q Turn the starting switch to OFF position. 7] When the throttle lock SET/ACCEL switch or throttle lock RESUME/DECEL switch are kept pressed for 0.5 second or more, acceleration or deceleration function is activated, allowing for fine setting of throttle level. However, if the throttle lock SET/ACCEL switch and throttle lock RESUME/DECEL switch are pressed at the same time, no control is available. 8] In the setting with auto deceleration function, if following conditions are satisfied, the throttle lock function is canceled temporarily; the transmission neutral status continues for 4 seconds or more, the work equipment lever neutral status continues for 4 seconds or more, in above duration, the throttle lock SET/ACCEL switch and the throttle lock RESUME/DECEL switch are not operated, the travel speed is 5 km/h or less. The engine is controlled according to the signal from the accelerator pedal. (The function is canceled temporarily similarly when the right brake pedal is depressed.) 9] In the setting with auto deceleration function, when the throttle lock function is canceled temporarily (4] or 8] above), if the transmission is not at the neutral or throttle lock or the work equipment lever is not at the neutral position, the throttle lock control status is automatically recovered.

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Electrical system Transmission control system

List of components

Throttle lock function switch

Throttle lock SET/ACCEL switch

Throttle lock RESUME/DECEL switch

Right brake pedal Control switch Momentary proximity switch Brake operation (GND) Brake not operated (OPEN)

Throttle lock display lamp In-switch LED Performed through electrical circuit

Switch Alternate composi3 position switch tion Switch theory ON(24 V) OFF(OPEN)

Momentary seesaw switch ON(GND) OFF(OPEN) Throttle position setting function The throttle amount is stored when it is ON (lock accelerator opening ratio) It is controlled with the edge of the input signal.

When the upper part of this swtich is pressed, "Without throttle lock auto deceleration function" is set. When the lower part of this swtich is pressed, "With Function throttle lock auto deceleration function" is set.

Resume function When this switch is pressed while the throttle lock function is cancelled with the right brake pedal (cancellation), the throttle lock function is recovered. It is controlled with the edge of the input signal. Accelerator function Deceleration function 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 throtpart of this switch tle opening set value tle opening set value is pressed, the rises in accordance lowers in accordance throttle lock funcwith the time the switch with the time the switch tion is OFF. is pressed. is pressed.

When the right brake pedal is depressed, Lights when the the throttle lock func- throttle lock function is temporarily tion switch is ON. cancelled.

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2) Throttle lock function status transition

1] 2] 3]

4]

Creation of lock accelerator opening for each status (Lock accelerator opening: Throttle lock level set by the throttle lock set switch) Status with throttle lock function disabled (default at key ON) Lock accelerator opening iActual accelerator opening The throttle lock function is enable and the opening is not determined. (Status immediately after the throttle lock function is started) Lock accelerator opening iActual accelerator opening 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].) 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) Lock accelerator opening iActual accelerator opening 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: Lock accelerator opening iActual accelerator opening

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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.

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.

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Electrical system Transmission control system

Modulation clutch (MOD/C) 1. Control function

Modulation clutch control Travel speed control function Driving force control function Tire slip control function Wall digging prevention control

10-3 6

Dump truck approach control function Emergency operation switch

2. Modulation clutch control The modulation clutch control has the following functions: 1) Travel speed control function This function can keep the travel speed below the maximum travel speed set with the travel speed control dial. Accordingly, if it is used during dump truck approach, the forward travel speed is restricted and the travel speed is kept low without operating the brake, thus the operator can work easily. It can be operated with the travel speed control ON/OFF dial only when necessary. <Operating conditions> q The travel speed control ON/OFF dial is ON. q Only when the transmission gear speed is F1 or F2 q Travel speed 1.5 km/h or more The maximum travel speed can be set as follows with the transmission gear speed and the travel speed control dial position.
Gear speed Maximum travel speed 1.57 km/h

When the 1st speed is selected When the 2nd 1.512 km/h speed is selected

2) Driving force control function The driving force determined with the driving force control dial can be reduced to the approriate value. In this way, slip of tires can be prevented on a slipper road such as clay (tuff loam), mud, etc. An operator can work without paying attention to control of the accelerator. With the driving force control dial position, the maximum driving force can be changed from 20% to 100%. <Operating conditions> q The transmission gear speed is F1. q Flat (See 3. Wall cutting prevention control) q During digging work 3) Tire slip control function When the driving force is reduced with the driving force control function and slip of tires still occurs, the driving force can be reduced along with detection of tire slip to minimize the slip level. <Operating conditions> q When tire slip option is enabled q The transmission gear speed is F1. q No operation of work equipment.

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3. Wall digging prevention control (work equipment protection control) To prevent abnormal load on the work equipment (bucket cylinder) in wall digging, the driving force is reduced by slipping the modulation clutch to protect the work equipment. a This function can be turned ON/OFF with the option setting of the multi monitor. It functions only when it is ON. a Status notification to KOMTRAX Plus Conditions are notified upon request from KOMTRAX Plus. q Status 0: Other than below. q Status 1: In buzzer sounding 4. Dump truck approach control function This function controls the modulation clutch automatically to increase the bucket rising speed and restrict the forward travel speed. By this, the dump truck approach distance can be shortened without operating the brake, thus the operator can work smoothly. 5. Emergency operation switch q The modulation clutch is controlled by ECMV. If a failure of the electrical system including controller occurs, the machine cannot be operated. q For this purpose, a circuit to connect the modulation clutch with the emergency operation switch is provided. a When the controller command current to E-POCV is increased, the hydraulic pressure is increased and the modulation clutch is directly connected. (It is disconnected when the engine is in stop.) a For a failure of a solenoid valve, the emergency escape plate for E-POCV is provided.

1) 2) 3) 4) 5) 6) 7) 8)

If the transmission controller detects power supply by direct connection using the emergency operation switch, the transmission controller stops the following controls. Dial driving force control Dial travel speed control Tire slip prevention control Wall digging prevention control Pressure reduction control in FR shifting Engine start assisting function Modulation clutch solenoid, disconnection, short-circuit failure Dump truck approach control

ECO lamp The ECO lamp lighting condition of the monitor panel is evaluated by the transmission controller and it is sent through communication. Lighting condition: q Throttle lock opening setting Z80% q Accelerator pedal opening setting Z80% q When E mode is selected (When E mode is selected for output to the engine controller) q Continued for 0.5 second.
q

Lighting OFF condition: When the lighting conditions are not satisfied

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Electrical system Transmission control system

Transmission controller

10-3 8

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Input/output signal
CN-L02 [DEUTSCH-24P] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name Angle sensor (L.R) rolling Left brake press sensor Traction dial GND_SIG_D Manual/Auto SW Startor switch (ING-C) Angle sensor (F.R) pitching Mod/C oil press sensor T/M oil temp. sensor GND_SIG_D Speed limit ON/OFF SW Mod/C direct signal Input and output signals Input Input Input Input Input Input Input Input Input Input Input and outPin No. Signal name put signals 13 Throttle lock with Auto decel SW Input 14 Speed limit dial Input 15 NC Input 16 PWR OUT_SENS Output 17 NC Input 18 R brake press sensor Input 19 Throttle lock without Auto decel SW Input 20 T/M temp. sensor 2 Input 21 GND_SIG_A 22 PWR_OUT_5V_0 Output 23 NC Input 24 F brake press sensor Input

CN-L03 [DEUTSCH-40P(1)] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 NC ECMV fillSW: Mod/C ECMV fill SW: 3rd NC AJSS shift down (NC) Parking brake signal ECMV fill SW: 1st NC NC Engine rev signal NC NC ECMV fill SW: 2nd NC AJSS shift down (NO) Direction lever: R ECMV fill SW: R NC NC Speed sensor Input Output Input Input Input Output Output Input Signal name Input and output signals Output Input Input Input Input Input Input Output Output Input Output Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 NC COMM_CAN_L NC PWR_CTR_EXT AJSS shift up (NC) Direction lever: N ECMV fill SW: F (N)MODE GND_SIG_P Mod/C speed sensor NC COMM_CAN_H NC NC AJSS shift up (NO) Direction lever: F Tire speed sensor (FL) S/T lever lock pressure SW GND_SIG_P NC Signal name Input and output signals Input/out put Input/out put Input/out put Input Input Input Input Input Input Input/out put Input/out put Input Input Input Input Input

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Electrical system Transmission control system

CN-L04 [DEUTSCH-40P(2)] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Signal name PWR_IN_BATT PWR_IN_BRY GND_ACT NC ECMV: F clutch ECMV: 2nd clutch F bypass solenoid T/M cutoff indicator (E)MODE TEST T/M cutoff ON/OFF SW PWR_IN_BATT PWR_IN_BRY GND_ACT PWR_CTR_KEY ECMV: R clutch ECMV: 3rd clutch R bypass solenoid Speed limit indicator SET/ACCEL SW T/M cutoff set SW Input and output signals Input Input Output Output Output Output Output Input Input Input Input Input Output Output Output Output Input Input Pin No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Signal name GND_PWR PWR_IN_BRY GND_ACT PWR_CTR_KEY ECMV: 1st clutch NC 1st bypass solenoid NC RESUME/DECEL SW Kick down SW GND_PWR GND_PWR GND_PWR PWR_OUT_5V_1 NC ECMV Mod/C R drain solenoid NC Right brake SW (P) MODE TEST Input and output signals Input Input Output Output Output Output Input Input

Output Output Output Output Output Input Input

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Electrical system Engine starting circuit

Engine starting circuit

10-341

Function q The safety on engine startup is secured by employing the neutral safety circuit in which the engine 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 function which, when the starting switch is put in START position, first circulates the engine oil to increase the oil pressure and then starts the engine.

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Electrical system Engine starting circuit

Operation When the starting switch is put in the ON position, the current flows from the starting switch terminal BR to the battery relay to close the contact point of the battery relay. This supplies power to the machine. q When the directional switch is put in the N (neutral) position the current flows in the coil in the neutral relay to make the contact points 5 and 3 conductive in the neutral relay. On the other hand, when the joystick steering control lever is in N (neutral), contact points 6 and 3 are conductive in the steering neutral relay. Here, when the starting switch is set to the START position, the current flows as follows: 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 neutral relay terminals 6 and 3 o pre-lubrication timer 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-lubrication 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 several seconds after the pre-lubrication is terminated, 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 engages 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.
q

10-342 The engine starts up, and the alternator starts to generate and output power from terminal B. At the same time, terminal L generates the same voltage as the one on terminal B and the current flows in terminal 2 in the safety relay to make the safety relay contact point open and shut off the power supply to the starting motor. Note that the current from alternator terminal L is supplied to the service meter, etc. as the signal indicating that the engine is running. When the forward and reverse switch is in N (neutral) and the joystick steering control lever is in other than N (neutral), the neutral relay and steering neutral relay shut off the circuit and the engine does not start.

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Electrical system Engine stopping circuit

Engine stopping circuit

10-343

Operation 10-343 q When the starting switch is turned OFF, the signal from the starting switch terminal ACC stops the signal sent to the electronic engine governor controller of Cummins Engine, and the fuel supply to the engine stops to stop the engine. When the engine speed decreases, the power supply from alternator terminal L stops as well as the power supply from the alternator terminal B, and the signals sent to service meters, etc. 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.

Emergency engine stop switch

10-343

Function 10-343 q When the emergency-stop of the engine is required on engine startup, the emergency engine stop switch is operated to stop the fuel supply to the engine and by cutting off the signal from the starting switch terminal ACC to the electronic engine governor controller of Cummins Engine, then, the engine stops.

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Electrical system Engine stopping circuit

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

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Electrical system Engine stopping circuit

Battery disconnect switch 10-345 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 machine is stored for a long time (a month or longer), 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 inoperative. q The clocks of the monitor and radio, and reception 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 battery 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 downloading switch (1) on the left side of rear frame and the lights-out of the indicators for VHMS operation indicators located next to the battery disconnect 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 machine setting is not lost)

* The figure shows a left battery box

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Electrical system Engine stopping circuit

Important Never turn OFF battery disconnect switch (2) while the engine is running or immediately after the engine 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 including 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 Maintenance Manual.

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Electrical system Electric parking brake control

Electric parking brake control

10-347

Outline q The parking brake is a wet multiple disc brake built in the transmission. When the parking brake solenoid valve is live with electricity, the oil pressure from the transmission pump is applied to the parking brake cylinder to release the parking brake. In contrast, when the current is shut OFF, the oil pressure is shut off from the transmission pump, the oil pressure in the parking brake is drained through the parking brake valve, and the force of spring activates the parking brake.

10-347 1. Parking brake switch 2. Parking brake emergency release switch 3. Parking brake display switch 4. Accumulator 5. Emergency brake switch 6. Parking brake solenoid valve 7. Parking brake emergency release solenoid valve 8. Neutralizer relay 9. Parking safety relay

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Electrical system Electric parking brake control

Function 1. Activating and releasing parking brake With the parking brake switch. 2. Automatic parking brake When the engine is stopped (starting switch is turned OFF), the parking brake works automatically to prevent an accident while an operator is leaving the seat. 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 escapability when stopped in the prohibited place (in the crossing), the transmission cannot be put in neutral when the emergency brake is activated.

10-348 6. Parking brake emergency release solenoid valve When the oil pressure cannot be supplied from the transmission pump due to a failure, etc., the parking brake emergency release switch on the operator's seat activates the emergency release solenoid valve to flow the accumulator charge pressure in the brake piping into the parking brake cylinder and release the parking brake.

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Electrical system Electric parking brake control

Operation 1. When the starting switch is turned OFF

10-349 10-349

When the starting switch is turned OFF, the battery relay opens, so the current does not flow in the parking brake circuit. Therefore, if the starting switch is turned OFF, regardless of whether the parking brake switch is ON (start) or OFF (release), the current does not flow into the parking brake solenoid valve and the parking brake works. (automatic parking brake).

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Electrical system Electric parking brake control

2. When starting switch is turned ON 2-1 When the parking brake switch is turned ON before the starting switch is turned ON

10-350 10-350

(1) As the current flows from battery (+) o starting switch o battery relay coil o ground, the battery 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. 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. Now that, as the current does not flow into the parking brake solenoid valve in this condition, the parking brake is active. Also, in this condition, the circuit between terminals 3 and 5 of neutralizer relay is open and the transmission controller put the transmission in neutral condition.

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Electrical system Electric parking brake control

2-2 When the parking brake switch is turned OFF before the starting switch is turned ON

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(1) As the current flows from battery (+) o starting switch o battery relay coil o ground, the battery relay becomes closed. However, in this case, the parking brake switch is turned OFF (release), 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 released automatically. Also, as the current does not flow into the transmission controller, the machine does not move.

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Electrical system Electric parking brake control

3. When the parking brake switch is turned OFF (release) When the parking brake switch is turned OFF after the starting switch is turned ON

10-352 10-352

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.

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Electrical system Electric parking brake control

4. When the parking brake switch is turned ON (activate)

10-353

When the parking brake switch is turned ON after working while the parking brake switch is turned OFF (release), the circuit is shown in the figure above. As the current does not flow in the parking brake solenoid valve, the oil pressure applied from the transmission pump to the parking brake cylinder is shut off, and at the same time, the pressurized oil in the parking brake cylinder is drained through the parking brake valve, so the force of spring activates the parking brake.

Also, at the same time, as the neutralizer relay is restored, the circuit between 3 and 5 becomes open, the signal does not flow from three neutralizer relay terminals to the transmission controller and the transmission becomes neutral. In this manner, by putting the transmission in neutral while the parking brake is working, the parking brake cannot be burned off even if the machine travels while the parking brake is applied.

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Electrical system Electric parking brake control

5. When the oil pressure of main brake decreases (emergency brake is activated)

10-354

Operation q When the oil pressure of the main brake line decreases, the emergency brake switch installed to the accumulator becomes open. Therefore, the current does not flow in the parking brake solenoid valve, so the pressurized oil in the parking brake cylinder is drained and the parking brake is activated. But, in this case, unlike when the parking brake switch is turned ON, the coil in the neutralizer relay is live with electricity.

10-354 Therefore, the signal flows into the transmission controller and the transmission clutch becomes connectable. Thus, the engine brake is also available when the emergency brake is working, so the braking distance can be shorter. In case the machine needs to be moved while the emergency brake is working (in the case that the emergency brake is activated when traveling a crossing), it becomes possible to move the machine by operating the transmission switch.

10-354

WA1200-6

Electrical system Electric parking brake control

6. Emergency-releasing parking brake

10-35

Operation q When the machine stops due to the problem of the engine, etc., the oil pressure from the transmission 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 emergency.

10-35

WA1200-6

10-355

Electrical system Electric parking brake control

Parking safety relay Neutralizer relay

Emergency brake switch

Parking brake emergency release switch

10-356

WA1200-6

Electrical system Sensor

Sensor
Ambient temperature sensor 10-357

10-357

Specifications 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 temperature ( C) Resistance (kz) Detected temperature ( C) Resistance (kz) -30 51.10 -20 30.32 -10 18.58 0 11.74 10 7.623

20 5.077

30 3.461

40 2.410

50 1.712

60 1.239

a: Thermal sensor mount diameter: 16 x 15 10-357 Function This sensor inputs the ambient temperature to the VHMS controller with a variation of the thermistor resistance.

WA1200-6

10-357

Electrical system Sensor

Air cleaner clogging sensor

10-358

1. Indicator 2. Spring 3. Adapter 10-358 Function 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 machine monitor lights up to output a warning.

10-358

WA1200-6

Electrical system Sensor

Coolant level sensor

10-359

1. Stopper 2. Float 3. Sensor 10-359 Function q The coolant level sensor is installed to the radiator upper tank. If the coolant level lowers below the specified level, the float lowers and the switch is turned OFF.

4. Plug 5. Tube 6. Connector

WA1200-6

10-359

Electrical system Sensor

Battery electrolyte level sensor

10-360

1. Body 2. Connector

3. Filter 4. Packing

5. Pin

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 exposed 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 2. Float 3. Arm

4. Body 5. Spring 6. Contact

7. Spacer

Function 10-361 q The fuel level sensor is installed to the side of the fuel tank. The float moves up and down according 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 2. Connector 3. Sensor 10-362 Function q This sensor is installed on the surface of the floor. It outputs the accelerator signal or idle validation signal depending on the accelerator pedal depressing angle. Accelerator signal The sensor detects the accelerator pedal displacement and the variable voltage is output from No. 2 pin. Idling validation signal The sensor detects the accelerator pedal operation. As the accelerator pedal is released, it outputs 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.

Output characteristics

10-362

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 direct connection switch is turned OFF. Resistance: 30 z

WA1200-6

10-363

Electrical system Sensor

Modulation clutch speed sensor Output shaft speed sensor 1 Output shaft speed sensor 2

10-364 10-364 10-364

1. Magnet 2. Locknut Function 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 transmission. 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 transmits it to the machine monitor via the network. The machine monitor converts the rpm into the travel speed and displays it.

3. Wiring harness 4. Connector 10-364

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 10-365 Function q The clogging sensor is installed to the filter section. If the filter is clogged and the pressure difference 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 Torque converter, transmission oil pressure sensor PPC oil pressure sensor

10-36 10-36 10-36

1. Sensor 2. Lead wire 3. Connector

Specifications 10-36 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 10-36 Function 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 modulation clutch with a voltage signal to the transmission controller.

10-366

WA1200-6

Electrical system Sensor

Transmission oil temperature sensor Torque converter oil temperature sensor Brake oil temperature sensor Hydraulic oil temperature sensor

10-367 10-367 10-367 10-367

1. Thermistor 2. Plug 3. Wiring harness 4. Connector 10-367 Function q The transmission oil temperature sensor senses the temperature of oil in the transmission case and the transmission controller uses the temperature to select the electronic modulation temperature 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 controller.

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 10-368 Function q Directional selector switch is held at a selected position. Transmission controller shifts the gear according to the signal from the directional selector 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 10-369 Function 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 running, and the condition is the same as the condition when the steering lock lever is set to LOCK position.

WA1200-6

10-369

Electrical system Sensor

AJSS lever angle sensor AJSS frame angle sensor

10-370 10-370

1. Connector 2. Case 3. Shaft 4. Element

5. Bearing 6. Contact 7. Mold

10-370 Function q The lever angle sensor is installed to the AJSS lever in the L.H. console, and frame angle sensor is installed to the follow-up linkage of the machine 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 Brake cooling oil level sensor Hydraulic oil level sensor

10-371 10-371 10-371

1. Connector 2. Bracket 10-371 Function q The sensors are installed on the side of the brake tank and hydraulic tank respectively. When the oil level lowers below the specified level, the float goes down to turn OFF the switch.

3. Float 4. Switch

WA1200-6

10-371

Electrical system Sensor

Brake accumulator pressure switch (front/rear)

10-372

1. Case 2. Tube 3. Connector 10-372 Function 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 2. Tube 3. Connector

Function 10-373 q When the brake pedal is depressed and the brake operating pressure is generated, the pressure switch contact is closed, the relay is operated and the stop lamp lights up. 10-373 10-373

Emergency brake pressure switch (front) Emergency brake pressure switch (rear)

1. Case 2. Tube 3. Connector

Function 10-373 q When the brake accumulator pressure lowers, the switch contact opens. Then, the circuit between 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 10-374 Function 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 parking 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) 10-375 Function q Switch A (1) installed on knob (4) of the lift arm control lever is a kickdown switch, and switch B (5) is a speed control ON/OFF switch. q Switch A (1) installed on knob (4) of the bucket control lever is a cancel switch of the load meter, and switch B (5) is a sub total switch. q Both switches A (1) and B (5) are automatic return type whose contact points close only while an operator pushing the switches. Kickdown switch 10-375 Operation q The kickdown switch is installed on the lift arm lever. When the switch is pushed while the conditions 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. Release (in manual shift mode) q When the directional switch is in "N" or "R" q When the upshift or downshift switch is pushed (forward 1st unchanged when downshift switch is pushed) q When the starting switch is turned OFF (in auto shift mode) When the directional switch is "N" q When the directional switch is changed between forward and reverse q When the upshift or downshift switch is pushed q When the travel speed increases q When the starting switch is turned OFF
q

WA1200-6

10-375

Electrical system Sensor

Front brake pressure sensor Rear brake pressure sensor Hydraulic oil pressure sensor Loader pump pressure sensor Lift arm bottom pressure sensor Lift arm head pressure sensor (load meter)

10-376 10-376 10-376 10-376 10-376 10-376

1. Sensor 10-376 Function q The sensor is installed to the inlet port circuit for the control valve. The sensor converts the pump delivery pressure to voltage and transmit it to the work equipment pump controller.

2. Connector 10-376 Operation q The oil pressure entering through the pressure inlet port presses the diaphragm of the oil pressure sensor, and deforms the diaphragm. 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 controller 10-37

10-37

Specifications 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 Under the operator's seat 10-37

10-37 Connector part CN-ORB1: DRC23-40P CN-ORB3: Communication antenna cable connector Antenna Specifications 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 10-37 10-37

10-37 Mounting position The antenna is installed on top of the pole on the rear left side of the machine. 10-37 Function It transmits the data collected and stored by VHMS controller to the computer center via the communication satellite.

WA1200-6

10-377

Electrical system Sensor

10-378 VHMS controller related a Details for basic precautions and outline, see "Testing and adjusting" 10-378 VHMS controller a For details of basic precautions, outlines, method of sending and receving data, and the procedure for the initial setup, see Testing and adjusting . Specifications 1. Voltage of power supply: DC20VDC30V 2. Dimension: W272 x D169 x H72 (mm) 10-378

10-378 Function Collect signals from each sensor and machine controller. 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 WA1200-6

Shop Manual

2-01

Machine model
WA1200-6

Serial number
60001 and up

20 Standard value table

20-1

WA1200-6

20-1

Contents

Contents
20 Standard value table Standard value table ............................................................................................................... 20Standard value table for engine ........................................................................................... 20Standard value table for chassis.......................................................................................... 203 3 4

20-2

20-2

WA1200-6

Standard value table Standard value table for engine

Standard value table

Standard value table for engine

Machine Model Engine Item Measurement condition E Low idle P Engine speed High idle a E: EconoE my mode P: Power P mode E Rated speed P Boost pressure 1,900 rpm At sudden acceleration Exhaust gas color At rated horsepower Blow-by pressure (15W-40 oil) Hydraulic (15W-40 oil) Engine oil temperature kPa (mmHg) Bosch index 1,800 196 {1,470} Max. 4.5 Max. 1.5 Min. 0.31 {Min. 3.16} 0.14 {1.43} 80 to 110 4,893 {498.95} 154 {1,155} Max. 4.5 Max. 1.5 0.26 {2.62} 0.137 {1.4} Max. 120 4,893 {498.95} rpm 1,850 to 1,950 1,800 to 2,000 625 to 675 1,850 to 1,950 575 to 725 1,800 to 2,000 Unit WA1200-6 SSDA16V 160E-2 Standard value for new machine 625 to 675 Repair limit 575 to 725

20-3

20-3

kPa (coolant temperature operating range) (mmH2O) At torque converter stall High idle Low idle Whole speed range (inside oil pan) MPa {kg/cm2} C N {kg}

(*) When the part is Measure belt tension by using a belt Fan belt tension new tension gauge When adjusting tension Push the midpoint between the drive Air conditioner compressor belt pulleyand the air conditioner comprestension sor pulley with a force of approx. 98 N {10 kg}.

N {kg}

4,893 {498.95}

4,893 {498.95}

mm

9 to 12.5

9 to 12.5

*: When a new part is installed, make sure to readjust after 24 hours operation.

WA1200-6

20-3

Standard value table Standard value table for chassis

Standard value table for chassis

Machine model Category Item NoF, R F, RoN Operating effort Upshift Downshift HOLD o RAISE RAISE o HOLD HOLD o LOWER LOWER o HOLD LOWER o FLOAT FLOAT o HOLD HOLD o DUMP HOLD o TILT TILT o HOLD HOLD o RAISE HOLD o LOWER HOLD o FLOAT HOLD o DUMP HOLD o TILT
q q

20-4
WA1200-6 Unit Standard value for new machine Repair limit

Measurement condition

Engine stopped Measure travel and operating ef- N {kg} fort from/at center of lever knob.

Lift arm Operating effort

10.8 1.0 10.8 1.0 {1.1 0.1} {1.1 0.1} 6.9 1.0 6.9 1.0 {0.7 0.1} {0.7 0.1} 6.9 1.0 6.9 1.0 {0.7 0.1} {0.7 0.1} 6.9 1.0 6.9 1.0 {0.7 0.1} {0.7 0.1} 18.6 (+5/0) 18.6 (+5/0) {1.9 (+0.5/0)} {1.9 (+0.5/0)} 14.7 (+5/0) 14.7 (+5/0) {1.6 + (+0.5/0)} {1.6 + (+0.5/0)} 10.8 (+5/0) 10.8 (+5/0) {1.1 + (+0.5/0)} {1.1 + (+0.5/0)} 18.6 (+5/0) {1.9 + (+0.5/0)} 14.7 (+5/0) {1.5 + (+0.5/0)} 11.8 (+5/0) {1.2 + (+0.5/0)} 18.6 (+5/0) {1.9 + (+0.5/0)} 14.7 (+5/0) {1.5 + (+0.5/0)} 37 10 37 10 45 10 45 10 37 10

Transmission switch

q q

Work equipment control levers

Engine speed: At low speed Hydraulic oil temperature: 45 to N {kg} 55 C

Bucket

18.6 (+5/0) {1.9 + (+0.5/0)} 14.7 (+5/0) {1.5 + (+0.5/0)} 11.8 (+5/0) {1.2 + (+0.5/0)} 18.6 (+5/0) {1.9 + (+0.5/0)} 14.7 (+5/0) {1.5 + (+0.5/0)} 37 10 37 10

Lift arm Travel

q q

Engine speed: At low speed Hydraulic oil temperature: 45 to 55 C

mm

45 10 45 10 37 10

Bucket

q q

Steering lever

Play
q q q q q q

Steering

Operating effort Operating angle

Engine stopped Measure on lever knob (at 149 mm from lever pivot point). mm Hold the rotation of the steering rotary valve. Flat, level, straight, dry, and paved N {kg} road Engine speed: At full speed Left lock to right lock Engine started Hydraulic oil temperature: 45 to 55 C Left lock to right lock degree

Max. 8

Max. 10

13.7 5.0 {1.4 0.5} 80 4 5.7 0.5

23.5 {2.4} 80 4 5.7 0.5 4.9 0.4

Operating time

Low speed Full speed

sec. 4.9 0.4

20-4

WA1200-6

Standard value table Standard value table for chassis

Machine model Accelerator pedal Category Item Measurement condition Unit

WA1200-6 Standard value for new machine 60 (+10/0) {6.1 (+1.0/0)} 57 40 300 (+30/0) {30.6 (+3/0)} 45 degree 53 15(+4/0) 16.9 mm 5 0.5 Max. 2.5 mm Max. 4.0 2 to 10 1,750 to 1,950 1,800 to 2,000 1,750 to 1,950 rpm P E P 1,800 to 2,000 1,600 to 1,950 1,650 to 2,000 2.5 0.15 {26 1.5} 2.7 0.15 {28 1.5} Max. 1.22 {Max. 13} 0.88 0.1 {9 1} 2.45 0.15 {25 1.5} 2.45 0.15 {25 1.5} 0.05 to 0.26 {0.5 to 2.7} 31.36 (+0.98/-0.29) {320 (+10/-3)} 1,700 to 2,000 1,500 to 2,000 1,550 to 2,000 2.5 0.15 {26 1.5} 2.7 0.15 {28 1.5} Max. 1.22 {Max. 13} 0.88 0.1 {9 1} 2.45 0.15 {25 1.5} 2.45 0.15 {25 1.5} 0.05 to 0.26 {0.5 to 2.7} 31.36 (+0.98/-1.27) {320 (+10/-13)} 3.72 (+0.39/-0.19) {38 (+4/-2)} Repair limit 60 (+10/0) {6.1 (+1.0/0)} 300 (+30/0) {30.6 (+3/0)} 1,650 to 2,000 1,700 to 2,000 1,650 to 2,000

Operating effort NEUTRAL (a1) Max. (a2) Operating effort

Operating angle

N {kg} a See figure A q Engine speed: At low speed q Hydraulic oil temperature: 45 to degree 55 C Right a See figure B a Right: Right brake Left: Left brake q Engine speed: At low speed q Hydraulic oil temperature: 45 to 55 C Left Right Left Right Left Right Left

N {kg}

Brake pedal

NEUTRAL (a1) Operating angle Max. (a2)

Play A B C

Tire

Fitting of wheel lock ring Clearance of wheel lock ring At torque converter stall

a See figure C q Tire inflation pressure: Specified pressure a E: Economy mode P: Power mode q Coolant temperature: Within operating range q Torque converter oil temperature: 60 to 80 C q Hydraulic oil temperature: 45 to 55 C q Gear shift lever: F4 or R4
q

E P E

Engine speed

Hydraulic stall At torque converter stall and Hydraulic stall Main relief pressure Low speed Full speed

Transmission and torque converter

Torque converter oil temperature: 60 to 80 C Torque converter oil temperature: 60 to 80 C Engine speed: At full speed

Torque converter relief (inlet) pressure Torque converter outlet oil pressure ECMV output (clutch) oil pressure 1st 2nd, 3rd MOD/C, F-R

q q q q q q q

Lubrication (oil cooler outlet) pressure Steering relief pressure Orbit-roll output pressure

MPa 2 Torque converter oil temperature: {kg/cm } 60 to 80 C Engine speed: At full speed Manual switch at ON Torque converter oil temperature: 60 to 80 C Engine speed: At full speed

q q

Hydraulic oil temperature: 45 to MPa 55 C {kg/cm2} 3.72(+0.19/0) Engine speed: At full speed {38 (+2/0)}

WA1200-6

Steering

20-5

Standard value table Standard value table for chassis

Machine model Category Item Measurement condition

q

WA1200-6 Unit Standard value for new machine Repair limit

Charge cut-in pressure Accumulator

q q

Engine speed: At full speed Hydraulic oil temperature: 45 to 55 C

Charge cut-out pressure

Checking to be perfomed when 17.6 (+0.59/0) the brake oil {180 (+6/0)} pressure warning MPa lamp goes off. {kg/cm2} Measure when brake oil pressure 20.6 (+1.47/0) starts lower{210 (+15/0)} ing after rising. 1st 6.1 0.3 11.1 0.6 18.9 0.9 km/h 1st 6.3 0.4 11.9 0.6 19.3 1.0 15.5 1.4 {158 14}

17.6 (+0.59/0) {180 (+6/0)}

20.6 (+1.47/0) {210 (+15/0)}

6.1 0.3 11.1 0.6 18.9 0.9 6.3 0.4 11.9 0.6 19.3 1.0 15.5 2.0 {158 20}

Forward Power train Travel speed Reverse

2nd 3rd gear speed

2nd 3rd gear speed

Brake oil pressure

Drop of brake oil pressure

Performance

Wear of disc Full speed Parking brake inlet pressure Parking brake At emergency release

Hydraulic oil temperature: 45 to 55 C q Engine stopped MPa q Keep brake pedal depressed at {kg/cm2} 4.9 MPa {50 kg/cm2} and measure drop in oil pressure after 5 minutes. q Tire inflation pressure: Specified pressure q Flat, level, straight, and dry paved road q Speed when applying brake: 20 m km/h, Delay in depressing pedal: 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 mm q Measure the piston stroke.
q

Max. 1.4 {14}

Max. 1.4 {14}

Wheel brake

Max. 6

Max. 6

0 2.65 0.2 {27 2}

7.0 2.65 0.2 {27 2} 2.94 0.29 {30 3} 2.65 0.2 {27 2} Stopped

q q

Torque converter oil temperature: MPa 60 to 80 C {kg/cm2} Engine speed: At Full speed

2.94 0.29 {30 3} 2.65 0.2 {27 2}

Parking brake pilot pressure Performance a See figure E Tire inflation pressure: Specified pressure q Flat paved road with a slope of 1/5 (11 deg. 20') and dry surface q Set machine in operating state.
q

Stopped

Disc thickness

mm

3.2 0.1

2.77

20-6

WA1200-6

Standard value table Standard value table for chassis

Machine model Category Item

q

WA1200-6 Unit Standard value for new machine 3.72 (+0.98/0) {38 (+10/0)} 3.72 (+0.2/0) {38 (+2/0)} Repair limit 3.72 (+1.47/-0.49) {38 (+15/-5)} 3.72 0.2 {38 2}

Measurement condition Hydraulic oil temperature: 45 to 55 C Engine speed: At full speed Hydraulic oil temperature: 45 to 55 C Engine speed: At full speed

PPC pump pressure

q q

PPC valve source pressure

q

EPC valve output pressure

Lift arm RAISE, FLOAT; Bucket DUMP, TILT Lift arm LOWER

PPC

q q q

Hydraulic oil temperature: 45 to MPa 55 C {kg/cm2} Engine speed: At full speed Work equipment control lever with full operation

3.72 (+0.2/0) {38 (+2/0)}

3.72 0.2 {38 2}

Control pump pressure

q q

Work equipment relief pressure

q

Hydraulic oil temperature: 45 to 2.94 (+0.98/0) 55 C {30 (+10/0)} Engine speed: At full speed Hydraulic oil temperature: 45 to MPa 31.36 55 C (+0.98/-0.29) 2 {kg/cm } {320 (+10/-3)} Engine speed: At full speed 13.5 0.5 5.3 0.5 Sec. 5.0 0.5 4.1 0.3 2.7 to 3.3

2.94 (+1.47/-0.49) {30 (+15/-5)} 31.36 (+0.98/-1.27) {320 (+10/-3)} 13.5 0.5 5.3 0.5 5.0 0.5 4.1 0.3 2.7 to 3.3

Lift arm speed

RAISE LOWER FLOAT Tilt back (At full stroke) DUMP (At full stroke) Bucket hinge pin drop amount

Work equipment valve

a See Fig. F q Hydraulic oil temperature: 45 to 55 C q Engine speed: At full speed q With no load a See Fig. G q Hydraulic oil temperature: 45 to 55 C q Engine speed: At full speed q With no load a See Fig. H q Hydraulic oil temperature: 45 to 55 C q Stop the engine and leave it for five minutes, then take measurement for 15 minutes. q Apply no load to bucket and set lift arm and bucket in level position.

Bucket speed

Hydraulic drift

Max. 250 mm Max. 100 (Does not include bucket hinge pin drop amount.)

Max. 250 Max. 100 (Does not include bucket hinge pin drop amount.)

Bucket cutting edge drop amount

WA1200-6

20-7

Standard value table Standard value table for chassis

a Drawing related to standard value table

20-8

WA1200-6

SEN0547510-00

30-1

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

3-01

Machine model
WA1200-6

Serial number
60001 and up

30 Testing and adjusting

30-1

WA1200-6

30-1

Contents

Contents
30 Testing and adjusting Tool for testing, adjusting and troubleshooting ....................................................................... Tools for testing, adjusting, and troubleshooting ................................................................. Safety precautions to follow before starting work ................................................................ Engine and cooling system ..................................................................................................... Testing engine speed........................................................................................................... Testing exhaust gas color .................................................................................................... Testing blow-by pressure..................................................................................................... Measuring engine oil pressure............................................................................................. Measuring exhaust gas temperature ................................................................................... Testing intake air pressure (boost pressure) ....................................................................... Testing radiator performance............................................................................................... Measuring wind speed across radiator and oil cooler.......................................................... Testing and adjusting fan belt tension ................................................................................. Testing and adjusting air conditioner compressor belt tension ............................................ Power train.............................................................................................................................. Adjusting speed sensor........................................................................................................ Testing and adjusting torque converter and transmission oil pressure................................ Traction control function checking procedure ...................................................................... Testing torque converter oil cooler performance ................................................................. Testing additional cooler fan speed ..................................................................................... Flushing procedure for torque converter and transmission circuit ....................................... Retrieval of disabled machine due to transmission valve failure ......................................... How to measure play of center hinge bearing ..................................................................... Measuring wear of rear axle support ................................................................................... Steering system ...................................................................................................................... Testing and adjusting steering oil pressure ......................................................................... Testing and adjusting emergency steering oil pressure....................................................... Bleeding air from steering circuit.......................................................................................... Testing and adjusting steering stopper bolt ......................................................................... Adjusting steering follow-up linkage..................................................................................... Testing steering EPC valve.................................................................................................. Testing and adjusting steering surge cut valve oil pressure ................................................ Testing and adjusting steering main relief valve oil pressure .............................................. Testing rotary valve output pressure.................................................................................... Brake system .......................................................................................................................... Testing brake performance .................................................................................................. Testing lowering of wheel brake oil pressure....................................................................... Testing of slack adjuster ...................................................................................................... Mesuring wear of wheel brake disc...................................................................................... Testing and adjusting accumulator charge pressure ........................................................... Testing brake accumulator oil pressure leakage ................................................................. Testing emergency parking brake valve oil leakage amount ............................................... Testing brake valve oil leakage amount............................................................................... Testing brake cooling oil pressure ....................................................................................... Testing brake oil cooler performance................................................................................... Testing parking brake performance ..................................................................................... Testing wear of parking brake disc ...................................................................................... Method of releasing parking brake manually ....................................................................... Testing parking brake oil pressure....................................................................................... 303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030304 4 9 13 13 15 16 17 18 19 20 21 22 23 24 24 26 29 30 31 32 33 36 38 39 39 40 42 44 45 50 52 54 56 58 58 59 60 61 62 64 66 69 74 76 76 77 78 79

30-2

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WA1200-6

Contents

Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas ......................................................................................................................... Hydraulic system .................................................................................................................... Testing and adjusting work equipment oil pressure by using multi monitor......................... Testing and adjusting work equipment oil pressure by using oil pressure gauge................ Testing and adjusting work equipment PPC oil pressure .................................................... Measuring point of hydraulic pump oil pressure .................................................................. Testing and adjusting PV control relief valve oil pressure ................................................... Testing and adjusting differential valve output oil pressure ................................................. Testing work pump ES valve output pressure ..................................................................... Testing and adjusting work pump CO (cut-off) valve oil pressure ....................................... Testing and adjusting work equipment pump TVC valve oil pressure ................................. Operation test of work equipment valve by work equipment speed (speed of work equipment is low)................................................................................................................. Testing hydraulic oil cooler performance ............................................................................. Bleeding air from hydraulic circuit........................................................................................ Releasing remaining pressure in hydraulic circuit ............................................................... Work equipment...................................................................................................................... Checking center hinge pin lubrication.................................................................................. Adjustment method of auto grease injector delivery ............................................................ Setting method of auto grease timer.................................................................................... Electrical system ..................................................................................................................... Testing and adjusting bucket proximity switch..................................................................... Adjusting lift arm potentiometer ........................................................................................... Adjusting lift arm levelness detecting switch........................................................................ Initial setting procedure for remote boom positioner (origin input method).......................... Checking proximity switch operation pilot lamp ................................................................... Adjusting AJSS lever angle sensor and frame angle sensor ............................................... Testing and adjusting potentiometer mounting position ...................................................... Procedure for testing diodes................................................................................................ Basic precautions for KOMTRAX Plus controller................................................................. Inspection and maintenance of KOMTRAX Plus controller ................................................. Initial setting procedure for KOMTRAX Plus controller ........................................................ Precautions for replacing KOMTRAX Plus controller .......................................................... Measurement procedure by downloading data in KOMTRAX Plus controller ..................... Measurement procedure by multi monitor ........................................................................... Special functions of multi monitor ........................................................................................ Pm Clinic................................................................................................................................. Outline of measurement procedure for Pm Clinic ................................................................ Preparation for measurement for Pm Clinic......................................................................... Pm clinic service ..................................................................................................................

30- 80 30- 86 30- 86 30- 88 30- 89 30- 91 30- 95 30- 97 30- 99 30- 101 30- 105 30- 107 30- 114 30- 117 30- 122 30- 123 30- 123 30- 125 30- 126 30- 128 30- 128 30- 129 30- 130 30- 131 30- 132 30- 133 30- 134 30- 137 30- 138 30- 147 30- 148 30- 165 30- 173 30- 177 30- 179 30- 236 30- 236 30- 237 30- 238

WA1200-6

30-3

Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting

Tool for testing, adjusting and troubleshooting

Tools for testing, adjusting, and troubleshooting
Testing and adjusting item Coolant temperature, oil temperature, and exhaust temperature Symbol B Part No. Part name Remarks -99.9 to 1,299 C

30-4

30-4

799-101-1502 Digital thermometer set 799-101-5002 Analog hydraulic tester 790-261-1204 799-101-5160 790-301-1271 790-261-1311 799-203-2440 799-401-2320 790-261-1331 790-261-1321 07376-50315 07221-20315 07222-00312 799-201-9002 Commercially available Commercially available 793-520-1805 793-520-1851 79A-264-0021 79A-264-0091 Commercially available Commercially available Commercially available 792-415-1200 792-415-110 792-415-1120 175-15-15540 238-15-12930 792-415-1150 792-415-1160 Digital hydraulic tester Nipple q Joint q Adapter Nipple Hydraulic gauge q Adapter q Adapter q Plug q Sleeve nut q Plug Handy smoke checker
q

1 2 3 4 C 5 6 7 8 9 10 11 1 G 2 H I J K L M 1 2

Hydraulic

Pressure gauge: 2.5, 6, 40, 60 MPa {25, 60, 400, 600 kg/cm2} Pressure gauge: 60 MPa {600 kg/cm2} PT 1/8 Male 10 x 1.25, PT 1/8 Male, female 14 x 1.5, PT 1/8 Male 18 x 1.5, PT 1/8 1 MPa {10 kg/cm2} 22 x 1.5 18 x 1.5 PPC hose side (Central block side) (Central block side) Bosch index: 0 to 9

Exhaust gas color Pedal depressing angle Brake oil pressure Operating effort Measuring stroke and hydraulic drift Work equipment speed Measurement of brake disc for wear Retrieval of disabled machine due to transmission valve failure Measuring voltage and resistance

Smoke meter Angle gauge

q

Brake test kit Nipple

Push-pull scale Ruler Stopwatch Vernier calipers Fixed valve assembly Cover q Spacer q Valve q Spring q Wrench q Adapter
q

0 to 294 N {0 to 30kg} 0 to 490 N {0 to 50kg}

(Note) Assembly part number 792415-1200 Since this kit is for dump trucks, it also includes 792415-1130 (spacer: 3rd, with stamping mark H) and 792415-1140 (spacer: 4th, with stamping mark L). For DT series 2P For DT series 3P For DT series 4P For DT series 6P For DTM series 2P Contact size #20 (commonly used for DT series and HD31 series) Contact size #16 (commonly used for DT series and HD31 series) Contact size #12 (commonly used for DT series and HD31 series)

1 N 2 O

79A-264-0211 Circuit tester 799-601-7600 799-601-7610 799-601-7620 799-601-7630 799-601-7650 799-601-7660 DT series connector adapter assembly q Adapter q Adapter q Adapter q Adapter q Adapter
q

Diagnosis of sensor and harness

799-601-7710 799-601-7720 799-601-7730

Contact Contact Contact

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WA1200-6

Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting

Testing and adjusting item

Symbol

Part No. 799-601-7740 799-601-7750

q

Part name Contact Contact

Remarks Contact size #8 (commonly used for DT series and HD31 series) Contact size #4 (commonly used for DT series and 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 799-601-2720

q

Adapter for MIC

Diagnosis of sensor and harness

799-601-2730 q Adapter for MIC 799-601-2740 q Adapter for MIC 799-601-7000 or 799-601-7100 or T-adapter assembly 799-601-7400 or 799-601-8000 799-601-7020 q Adapter for X 799-601-7030 q Adapter for X 799-601-7050 799-601-7060 799-601-7080 799-601-7090 799-601-7120 799-601-7130 799-601-7140 799-601-7150 799-601-7160 799-601-7190
q q q q q q q q q q

For M1C-13P (not included in 799-601-2800, 799-601-7100, 799-601-8100) For MIC-17P For MIC-21P

Adapter for SWP Adapter for SWP Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M Adapter for S (white) Adapter for S (blue) Adapter for 040

799-601-7210 q Adapter for 040 799-601-7220 q Adapter for 040 799-601-4101 or 799-601-4201 or T-adapter assembly 799-601-9000 or 799-601-9200 799-601-9020 q Adapter for DT 799-601-9030 799-601-9040 799-601-9050
q q q

For X-2P For X-3P For SWP-6P (not included in 799-601-8000) For SWP-8P (not included in 799-601-8000) For M-1P (not included in 799-601-7000, 799-601-7100) For M-2P For M-4P For M-6P For S-8P For S-10P (white) For S-12P (blue) (not included in 799-601-8000) For 040-12P (not included in 799-601-7000, 799-601-7100) For 040-16P For 040-20P

Adapter for DT Adapter for DT Adapter for DT

For DT-2P For DT-3P (not included in 799-601-4101, 799-601-4201) For DT-4P For DT-6P (not included in 799-601-4101, 799-601-4201)

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Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting

Testing and adjusting item

Symbol

Part No. 799-601-9060 799-601-9070 799-601-9110

q

Part name Adapter for DT (gray)

Remarks

Diagnosis of sensor and harness

799-601-7400 799-601-7180 799-601-7500 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 Out of kit 799-601-7310 07063-41210 1 799-608-3211

For DT-8P (not included in 799-601-4101, 799-601-4201) For DT-8P (black) (not included in q Adapter for DT (black) 799-601-4101, 799-601-4201) For DT-12P (gray) (not included in q Adapter for DT (gray) 799-601-4101, 799-601-4201) T-adapter assembly q Adapter for 040 For 040-8P T-adapter assembly q Adapter for APM070 For APM070-10P q Adapter for APM070 For APM070-12P q Adapter for APM070 For APM070-14P q Adapter for APM070 For APM070-18P q Adapter for APM070 For APM070-20P (not included in kit) Adapter for SWP For SWP-12P Element (for flushing) Standard element installed 07063-01210

Flushing procedure for torque converter and transmission hydraulic circuit Initial setting and setting after replacement of KOMTRAX Plus controller

2 Q 3 4

Filling gas into accumulator R

KOMTRAX Plus analysis tool 799-608-3220 Wiring harness Commercially Note type PC available 21T-06-64590 Coupling assembly 21T-06-64392 Wiring harness 792-610-1701 Gas charge tool kit 792-610-1700 q Gas charge tool 07000-11009 q O-ring 792-610-1702 Gas charge tool kit 792-610-1700 q Gas charge tool 07000-11009 q O-ring 792-610-2310 q Extension 792-610-1310 Nipple (For Russia) 792-610-1320 Nipple (For USA) 792-610-1330 Nipple (For USA) 792-610-1350 Nipple (For Germany) 792-610-1360 Nipple (For UK)

(OS: Windows 98/2000) Pm clinic For old type accumulators

For old and new type accumulators GOST CGA No.351 ASA B-571-1965 DIN 477-1963 NEN3268-1966 SIS-SMS 2235/2238 BS 341 Part1-1962 Digital display: 6.0 to 99,999 rpm

Measuring wind speed Measuring fan speed

S T

Commercially Anemometer available 799-205-1100 Tachometer kit

30-6

WA1200-6

Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting

Testing and adjusting item

Symbol

Q'ty

Part No.

Part name

Remarks

799-601-4101 or T-adapter assembly 799-601-4201 799-601-4350

q

1 For DRC60, ECONO 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 1 sensor (PACKARD 2P) For engine (CRI-T3) oil temperature sensor (PACKARD 2P) For engine (CRI-T3) ambient pressure 1 sensor (AMP 3P) For engine (CRI-T3) boost pressure 1 sensor and boost temperature sensor (SUMITOMO 4P) For engine (CRI-T3) G (backup) sensor 1 (SUMITOMO 3P) For engine (CRI-T3) supply pump PCV 1 1 and PCV 2 sensors (SUMITOMO 3P) For engine (CRI-T3) NE sensor 1 (FRAMATOME 3P) For engine (CRI-T3) common rail fuel 1 pressure sensor (AMP 3P) For engine controller DRC26-50P 1 (does not include in Kit No. 799-601-4201) For engine controller DRC26-60P 1 (does not include in Kit No. 799-601-4201) For engine controller DTP-4P 1 (Included in Kit Nos. 799-601-9000 and 799-601-9100, too) For DT 4P (Included in Kit Nos. 1 799-601-9000 and 799-601-9200, too) For DT 2P (Included in Kit Nos. 1 799-601-9000 and 799-601-9200, too)

T-box

795-799-5530

Socket

799-601-4140 799-601-4230 Troubleshooting for engine, controller sensor, and actuator 799-601-4330 799-601-4340 799-601-4130 799-601-4190 799-601-4211 799-601-4220 799-601-4260 799-601-9040 799-601-9020

Socket Socket Socket Socket T-adapter T-adapter T-adapter T-adapter Adapter for DTP T-adapter T-adapter

q q q q

q q

Troubleshooting for machine wiring harness

799-601-9000 or 799-601-9100 T-adapter assembly or 799-601-9300 1 For ECONO (Max. 24P) 799-601-9320 q T-box 799-601-4101 q T-adapter assembly 799-601-4350 q T-box 1 For DRC60, ECONO (Max. 60P) 799-601-7000 or 799-601-7100 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) 1 For AMP040 16P 799-601-7210 q T-adapter 799-601-7220 q T-adapter 1 For AMP040 20P 799-601-7090 q T-adapter 1 For M 2P

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Tool for testing, adjusting and troubleshooting Tools for testing, adjusting, and troubleshooting

Testing and adjusting item

Symbol

Q'ty

Part No. 799-601-7120 799-601-7130 799-601-7340 799-601-7140 799-601-7350 799-601-7170 799-601-7330 799-601-7060 799-601-7310 799-601-7070
q q q q q q q

Part name T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter

Remarks For M 4P For M 6P For M 8P (Kit No. is not registered) For S 8P For S 12P (white) (Kit No. is not registered) For S 16P (blue) For S 16P (white) (Kit No. is not registered) For SWP 8P (does not include in Kit No. 799-601-8000) For SWP 12P (does not include in Kit No. 799-601-8000) For SWP 14P (does not include in Kit No. 799-601-8000) For SWP 16P (Kit No. is not registered) For X 1P For X 2P For X 4P

1 1 1 1 1 1 1 1 1 1 1 1 1 1

Troubleshooting for machine wiring harness

799-601-7320 q T-adapter 799-601-7010 q T-adapter 799-601-7020 q T-adapter 799-601-7040 q T-adapter 799-601-7500 T-adapter assembly 799-601-7520 q T-adapter 799-601-9000 or T-adapter assembly 799-601-9200 799-601-9040 799-601-9020 799-601-9030 799-601-9050 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9270
q q q q q q q q

1 For AMP070 12P

T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter T-adapter

1 1 1 1 1 1 1 1 1

For DT 4P (included in Kit Nos. 799-601-4101 and 799-601-4201, too) For DT 2P For DT 3P For DT 6P For DT 12P (gray) For DT 12P (black) For DT 12P (green) For DT 12P (brown) For HD36 24-21P (does not include in Kit No. 799-601-9200) (included in Kit No. 799-601-9100, too)

799-601-9300 T-adapter assembly 799-601-9360 q T-adapter 799-601-9350 q T-adapter 799-601-7360 T-adapter 799-601-7370 T-adapter 799-601-9420 T-adapter

1 1 1 1

For pump controller DRC26-24P For pump controller DRC26-40P For 5P-relay (Kit No. is not registered) For 6P-relay (Kit No. is not registered) For AMP 3P (pressure sensor) 1 (included in Kit No. 799-601-4101 and 799-601-4201, too)

30-8

WA1200-6

Tool for testing, adjusting and troubleshooting Safety precautions to follow before starting work

Safety precautions to follow before starting work

1. Perform repair and maintenance with the machine placed on a stiff and flat ground. 1) Wash the machine. a Thoroughly wash the portions to be removed.

30-9

4) Move parking brake switch (3) to the "ON (Parking)" position.

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 machine 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.

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30-9

Tool for testing, adjusting and troubleshooting Safety precautions to follow before starting work

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. 1) Operate the work equipment control levers (lift arm and bucket) back and forth slowly two or three times in full strokes. a Hydraulic sound will cease when there is no more pressure remaining in the circuit.

4) Loosen hydraulic tank cap (4). (Hold the cap at a position where a hissing sound is heard.)

2) Move work equipment lock lever (1) to the "LOCK" position.

5) Depress the brake pedal ten times in full strokes. (Until no hydraulic sound is heard.)

30-10

WA1200-6

Tool for testing, adjusting and troubleshooting Safety precautions to follow before starting work
k

6) Loosen brake tank filler cap (3). (Hold the cap at a position where a hissing sound is heard.)

If refrigerant gas gets in your eyes, you may lose your sight. And if it touches your skins, you may suffer from frostbite. Accordingly, put on the protective eyeglasses, 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 disconnect 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, collect 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 Decomposition of Freon."

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30-11

Tool for testing, adjusting and troubleshooting Safety precautions to follow before starting work

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

Engine and cooling system Testing engine speed

Engine and cooling system

Testing engine speed
k

30-13
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.) 3. Display item "ENGINE SPEED" (page 1/4 of PM-CLINIC MENU).

30-13

Be sure to follow "Safety precautions to follow before starting work". k When measuring, confirm that there are no persons around the machine. a Measure the engine speed under the following conditions. q Coolant temperature: Within operating range q Hydraulic oil temperature: 45 to 55 C q Power train oil temperature: 70 to 90 C 30-13 Measuring low idle and high idle speeds 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 value is released.

When changed to this screen (SERVICE MENU 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

Engine and cooling system Testing engine speed

30-14 Measuring torque converter stall speed 1. Set transmission cut-off switch (1) to OFF and depress left brake (4) securely (to switch the transmission cut-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 (7) to upshift to "3rd". (Note) 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 (6), 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.

Measuring torque converter + hydraulic stall 30-14 speed 1. In the same way as "Measuring low idle and high idle speeds", display item "Engine speed" on the real-time monitor screen. 2. 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). 3. Set transmission auto/manual shift selector switch (3) to "ON (Manual)". a At this time, the gear shift mode is in "2nd". 4. Press the upshift switch to upshift to "3rd". (Note) 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 forward and reverse (FNR) switch (6), in "F" or "R". 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 machine Low idle 625 to 675 High idle 1,850 to 1,950 Torque converter stall 1,800 to 2,000 Hydraulic stall 1,800 to 2,000 Full stall 1,650 to 2,000 Engine mode fixed to E mode (rpm) Standard value Measurement condifor new tion machine Low idle 625 to 675 High idle 1,850 to 1,950 Torque converter stall 1,750 to 1,950 Hydraulic stall 1,750 to 1,950 Full stall 1,600 to 1,950 Repair limit 575 to 725 1,800 to 2,000 1,650 to 2,000 1,650 to 2,000 1,500 to 2,000 Repair limit 575 to 725 1,800 to 2,000 1,700 to 2,000 1,700 to 2,000 1,550 to 2,000

30-14 Measuring hydraulic stall speed 1. Relieve the lift arm cylinder or bucket cylinder on the extraction side with engine at full throttle, and measure the engine speed.

30-14

WA1200-6

Engine and cooling system Testing exhaust gas color

Testing exhaust gas color

a Testing tools
Symbol 1 G 2
k

30-15

Part No. 799-201-9002 Commercially available

Part name Handy smoke checker Smoke meter

Be sure to follow "Safety precautions to follow 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 engine. 1. Testing by using handy smoke checker G1 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.

2) Connect the probe hose, receptacle of the accelerator switch, and air hose to tool G2. a Limit the supplied air pressure to 1.5 MPa {15 kg/cm2} or below.

2. Testing with smoke meter G2 1) Insert the probe of smoke meter G2 into the outlet of the exhaust pipe and fix it to the exhaust pipe by tightening the clip.

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. a Fit the filter paper securely so that the exhaust gas will not leak. 5) Turn on the power switch of tool G2. 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

Engine and cooling system Testing blow-by pressure

Testing blow-by pressure

k

30-16
4. Test the blow-by pressure when the engine is at full speed and the torque converter is stalled. k When taking measurements, take care not to touch hot parts or rotating parts. a The blow-by pressure may vary largely with the engine condition. If the measured value is judged unusual, make a check for increase of oil consumption, bad exhaust gas color, early deterioration or contamination of oil, etc. which are related to the unusual blow-by pressure. 5. If [F3] switch is pressed when reading the blow-by pressure, the value is held. a If the hold [F3] switch is pressed again, the value is released. a Blow-by pressure standard values
kPa (mmH2O) Conditions Standard value for new machine Repair limit Max. 3.29 (330) When engine at full speed and torque Max. 1.25 (127) converter stalling

Be sure to follow "Safety precautions to follow before starting work". a Raise coolant temperature to operating range, then perform the test. q Check on the Pm Clinic menu screen (1/4). 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.

3. Display item "Blowby pressure" (page 2/4 of "PM-CLINIC MENU" screen).

30-16

WA1200-6

Engine and cooling system Measuring engine oil pressure

Measuring engine oil pressure

k

30-17
5. If [F3] switch is pressed when reading the engine oil pressure, the value is held. a If the hold [F3] switch is pressed again, the value is released. a Engine oil pressure standard values q 15W to 40 oil q Coolant temperature: Within operating range
(MPa {kg/cm2}) Conditions High idle Low idle Standard value for new machine Min. 0.31 {Min. {3.16}} 0.14 {1.43} Repair limit 0.26 {2.62} 0.113 {1.15}

Be sure to follow "Safety precautions to follow before starting work". a Raise coolant temperature to operating range, then measure. q Check on the Pm Clinic menu screen (1/4). 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.

3. Display item "Engine oil pressure" (page 1/4 of "PM-CLINIC MENU" screen).

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

Engine and cooling system Measuring exhaust gas temperature

Measuring exhaust gas temperature

k

30-18
30-18 Measurement procedure 1. When measuring the maximum value in troubleshooting Operate the machine actually and measure the maximum value. (Note) The exhaust gas temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it. a Corrected value = Measured value + 2 x (Conversion ambient temperature - Ambient temperature) a Conversion ambient temperature is assumed to be 20 C. 2. Procedure for measuring periodically for preventive 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 following drawing higher.)

Be sure to follow "Safety precautions to follow before starting work". a Raise coolant temperature to operating range, then measure. q Check on the Pm Clinic menu screen (1/4). 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.

3. Display item "Exhaust gas temperature" (page 2/4 of "PM-CLINIC MENU" screen).

4. If [F3] switch is pressed when reading the exhaust gas temperature, the value is held. a If the hold [F3] switch is pressed again, the value is released.

3) Measure the temperature when it starts to decrease and then stabilizes. a If only the torque converter is put in the stalled condition, the torque converter will overheat before the exhaust temperature stabilizes.

30-18

WA1200-6

Engine and cooling system Testing intake air pressure (boost pressure)

Testing intake air pressure (boost pressure)

k

30-19

Be sure to follow "Safety precautions to follow before starting work". a Raise coolant temperature to operating range, then measure. q Check on the Pm Clinic menu screen (1/4). 1. Select "SERVICE MENU SELECT" on the multi monitor screen.

5. If [F3] switch is pressed when reading the boost pressure, the value is held. a If the hold [F3] switch is pressed again, the value is released. a Boost pressure standard values
(kPa {mmHg}) Conditions Standard value for new machine 196 15 {1,470 113} Repair limit 154 {1,155}

2. Use item selection switches F3 and F4 to select Pm Clinic, and then press F6 switch to display the "PM-CLINIC MENU" screen.

1,900 rpm

3. Display item "Boost pressure" (page 2/4 of "PM-CLINIC MENU" screen).

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 pressure) should be tested while the engine is running at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter.

WA1200-6

30-19

Engine and cooling system Testing radiator performance

Testing radiator performance

k

30-20

Be sure to follow "Safety precautions to follow before starting work".

30-20 Testing condition 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 temperature gun and calculate the difference.
q

Aim a temperature gun to inlet tube (1) and outlet tube (3) to measure the temperature and calculate the difference. a Temperature difference standard value: 6 to 8 C

30-20

WA1200-6

Engine and cooling system Measuring wind speed across radiator and oil cooler

Measuring wind speed across radiator and oil cooler

a Testing tools
Symbol S
k

30-21

Part No. Commercially available

Part name Anemometer

2. Divide the rear area of the hydraulic oil cooler into eight rows (1 to 8) and eight columns (A to H) to decide the positions to measure the wind speed.

Be sure to follow "Safety precautions to follow before starting work". 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 1st 2nd 3rd 4th 5th 6th 7th 8th B C D E F G H

Testing procedure 1. Open radiator grille (1).

30-21

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

Engine and cooling system Testing and adjusting fan belt tension

Testing and adjusting fan belt tension

k

30-2

Be sure to follow "Safety precautions to follow before starting work". 30-2

Checking 1. Remove fan covers (A) and (B).

30-2 Adjusting 1. Loosen bolt (2) and adjust the tension with bolt (3). a When bolt (3) is turned clockwise, the tension 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

Engine and cooling system Testing and adjusting air conditioner compressor belt tension

Testing and adjusting air conditioner compressor belt tension

k

30-23

Be sure to follow "Safety precautions to follow before starting work".

30-23 Checking Press the belt at the midpoint between drive pulley (1) and air conditioner compressor pulley (2) with a force of approx. 98 N {10 kg}, and measure the belt deflection b. a Deflection of belt (standard value) b: 9 to 12.5 mm

30-23 Adjusting 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
k

Adjusting speed sensor

Be sure to follow "Safety precautions to follow before starting work".

30-24

30-24

30-24 Engine speed sensor 1. Screw in speed sensor (1) until its tip touches gear (2), and then back it off by 1/2 to 1 turn. 2 Threaded portion: Liquid gasket (LG-5) 2. Tighten lock nut (3). 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 arranging the wiring. a Take care not to let iron particles stick to the speed sensor tip or damage it.

30-24 Transmission output shaft speed sensor 1. Screw in transmission output shaft speed sensor (4) until its tip touches gear (5), and then back it off by 1/2 to 1 turn. 2 Threaded portion: Liquid gasket (LG-5) 2. Tighten lock nut (6). 3 Locknut: 49.0 to 68.6 Nm {5.0 to 7.0 kgm}

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 follow before starting work".

30-26 Testing Engine coolant temperature: Within operating range q Torque converter oil temperature: 60 to 80 C k Chock the wheels to prevent the machine from moving. 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.
q

2. Modulating 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. 3) Display item "T/M MOD (transmission modulating) pressure (B)" (page 3/4 of "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 pressure (A)" (page 3/4 of "PM-CLINIC MENU" screen).

a Modulating pressure standard value 4) Start the engine and measure the oil pressure while running it at high idle. a Main relief pressure standard value
Conditions Torque converter oil temperature: 60 to 80 C Standard value 2.45 to 2.85 MPa {25 to 29 kg/cm2} Measuring point F, R 1st 2nd 3rd gear speed Standard value 2.3 to 2.6 MPa {23.5 to 26.5 kg/cm2} 2.1 to 2.4 MPa {21.5 to 24.5 kg/cm2} 2.3 to 2.6 MPa {23.5 to 26.5 kg/cm2} 2.3 to 2.6 MPa {23.5 to 26.5 kg/cm2}

30-26

WA1200-6

Power train Testing and adjusting torque converter and transmission oil pressure

3. Torque converter inlet oil 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. 3) Display item "T/C (torque converter) inlet pressure (C)" (page 3/4 of "PM-CLINIC MENU" screen).

4) Start the engine and measure the oil pressure while running it at high idle. a Torque converter outlet pressure standard value
Conditions Torque converter oil temperature: 60 to 80 C Standard value 0.78 to 0.98 MPa {8 to 10 kg/cm2}

5. Lubrication valve pressure 1) Select "Service Menu" 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. 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 pressure while running it at high idle. a Torque converter inlet pressure standard value
Conditions Torque converter oil temperature: 60 to 80 C Standard value 1.08 to 1.28 MPa {11 to 13 kg/cm2}

4. Torque converter outlet oil 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. 3) Display item "T/C (torque converter) outlet pressure (D)" (page 3/4 of "PM-CLINIC MENU" screen).

4) Start the engine and measure the oil pressure while running it at high idle. a Lubrication valve pressure standard value
Conditions Torque converter oil temperature: 60 to 80 C Standard value 0.05 to 0.15 MPa {0.5 to 1.5 kg/cm2}

6. If [F3] switch is pressed while reading the oil pressure, the value is held. a If the hold [F3] switch is pressed again, the 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 Testing and adjusting torque converter and transmission oil pressure

3) Start the engine and measure the oil pressure for the 1st, 2nd, and 3rd clutches under the following conditions. 1] Keep the FNR (forward-reverse) switch in "N" (NEUTRAL) position. 2] Set the auto shift / manual selector switch to "ON" (manual). 3] Using the upshift and downshift switches, select each gear speed. 4] Measure with the engine running at full speed. 4) Start the engine and measure the oil pressure for the forward and reverse clutches under the following conditions. 1] Set the transmission cut-off switch to "OFF" (extinguish) position. 2] Turn parking brake switch OFF. 3] Depress brake pedal. 4] Set the auto shift / manual selector switch to "ON" (manual) position, and then select the "3rd" gear using the upshift switch. 5] With the brake pedal depressed, set the 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 1st F, R, 2nd, 3rd Standard value 2.10 to 2.40 MPa {21.5 to 24.5 kg/cm2} 2.30 to 2.60 MPa {23.5 to 26.5 kg/cm2}

Adjusting 30-28 k When adjusting the oil pressure, stop the engine. a Do not perform any adjustment if the main relief pressure cannot be measured accurately. a If the main relief pressure is out of the standard value, adjust according to the following procedure. 1. Adjustment of transmission main relief pressure 1) To adjust oil pressure, remove the cover (1) and increase or decrease the number of shims (2). a Loosen the bolts on the cover (1) gradually while releasing the springs (3) and (4). a Standard thickness of shims: 2.0 mm a Amount of adjustment per shim (t=0.5 mm): 42.17 kPa {0.43 kg/cm2} a The relief pressure will increase by adding shims, and decrease by reducing shims. q Shim part No.: 42C-13-16220

30-28

WA1200-6

Power train Traction control function checking procedure

Traction control function checking procedure

1. Regarding the traction control function, put the multi monitor into "Real-time monitor" mode and check on the "Traction setting input values" screen 1) Select "SERVICE MENU SELECT" on the multi monitor screen. 2) Use item selection switches F3 and F4 to select Real-time monitor, and then press F6 switch to display the "T/M Controller" screen. 3) Display item "Traction setting input values" (page 6/12 of T/M Controller screen).

30-29

2. Under the following condition, the display is normal if the reading is 100% when the drive force control dial of MOD/C set at "MAX", and 0 to 40% when set at "MIN". Conditions 1) Engine low idle (engine speed: 650 rpm) 2) F1 shift 3) Depress the right brake pedal. 4) Set transmission cut-off switch to ON position. 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 driver'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

a Testing tools
Symbol B Part No. 799-101-1502 799-101-5002 C 1 790-261-1204
k

30-30

Part name Digital thermometer kit Oil pressure gauge kit (analog) (Pressure gauge: 2.5 MPa {25 kg/cm2}) Oil pressure gauge kit (digital) q Nipple

799-101-5160

Be sure to follow "Safety precautions to follow before starting work".

2. Performance check 1) Start the engine and perform testing. a Measure the followings with the engine at full speed and the torque converter in the stalled condition. a Inlet pressure: 0.3 to 0.5 MPa {3 to 5 kg/cm2} Outlet pressure: 0.15 to 0.25 MPa {1.5 to 2.5 kg/cm2} a Oil temperature difference: 11 to 13 C 2) When completing all measurements, stop the engine and install plugs (5).

30-30 Testing condition Engine speed: Full speed q Torque converter oil temperature: 60 C a To test the torque converter oil cooler performance, measure the oil pressure at inlet and outlet sides and the difference in temperature.
q

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

a Testing tools
Sym bol 1 7 T Part No. 799-101-5002 Part name Hydraulic tester (analog) 40 MPa {400 kg/cm2} Hydraulic tester 790-261-1204 (digital) 790-261-1331 Adapter (M22) 799-205-1100 Tachometer kit

30-31
3. Run the engine at high idle and measure the fan speed.
Standard value (rpm) Specifications Engine speed Fan speed P mode fixed 1,850 to 1,950 E mode fixed 1,850 to 1,950

2,000 100

30-31 Testing conditions q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". 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 reflection 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

a Dust such as metal powder in the hydraulic circuits of the torque converter and transmission shortens the life of the torque converter and transmission and causes internal breakage. To remove dust in the hydraulic circuit, perform flushing. 1. Flush the hydraulic circuit in the following cases. 1) When metal powder flows into the circuit because of damage to the torque converter, transmission and hydraulic components. 2) When the torque converter and transmission are overhauled or modified. 2. Install the element for flushing. 1) Drain the oil from the filter. 2) Remove the two transmission oil filters and install two elements for flushing. a Install the removed parts after cleaning them and the inside of the case. 3. Add oil to the transmission case. q Add new 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. 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 approximately 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, reverse, 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

5. Replace the filter elements for flushing. 1) Replace the elements used for flushing with standard elements following the same procedure as in step 2-1). k Be sure to replace with standard elements because the filter elements used for flushing causes premature clogging if used for a prolonged time. 2) Add the oil and check the oil level again. 6. Replace the transmission last chance oil filter. 1) Remove case (1) of the last chance filter by turning portion A using a wrench. a If there is dust in the filter case, clean it. 2) Remove element (2) and replace it with a new element. 3) Install a new O-ring (3) to the periphery of the case. a Apply a thin film of grease on the periphery of the O-ring. 4) Install the case. 3 Case mounting bolt: 58.8 to 73.55 Nm {6 to 7.5 kgm}

30-32

WA1200-6

Power train Retrieval of disabled machine due to transmission valve failure

Retrieval of disabled machine due to transmission valve failure

a Testing tools
Symbol N Part No. 792-415-1200 Part name Fixed valve assembly

30-3

a If the machine is disabled due to failure of a transmission valve part (electrical system, solenoid 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 failure, 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 purposes. k When moving the machine by this method, observe the procedure and ensure safety. k Be sure to follow "Safety precautions to follow before starting work". k Lower the work equipment completely to the ground, apply the parking brake, and chock the wheels to prevent the machine from moving. 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 ECMV. 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 assembly".

WA1200-6

30-33

Power train Retrieval of disabled machine due to transmission valve failure

4. Remove either of the two ECMV solenoids (15) depending on the direction of travel (forward or reverse), and install a fixed valve assembly (tool N1) there. q For forward travel: F solenoid and 2nd solenoid q For reverse travel: R solenoid and 2nd solenoid a If a wrong solenoid is removed, the transmission may break. Be careful. a Take care that mud or dirt will not enter the removed solenoids and valves.

1) Assembly of fixed valve assembly (tool N1) 1] Install spring (17) to cover (16). 2] Install the following spacer (18)(792-415-1120 stamped with R, 1, 2).
Required spacer (18) Stamp R, 1, 2

a The fixed valve assembly (tool N1) includes 792-415-1130 (spacer: stamped with 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 solenoid and ECMV.

30-34

WA1200-6

Power train Retrieval of disabled machine due to transmission valve failure

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 depress the brake pedal and ensure that there are no persons or obstacles in the direction of travel and around the machine.

WA1200-6

30-35

Power train How to measure play of center hinge bearing

How to measure play of center hinge bearing

k

30-36

Be sure to follow "Safety precautions to follow before starting work". 30-36

Procedure 1 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.

30-36 Procedure 2 (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 (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.

30-37

Procedure 4 1. Repeat measuring procedures 2 and 3 a few times to minimize variation in the data.
(1) 1st time Measured value mm mm (2) 2nd time Standard value: 0.61 mm mm mm (3) 3rd time mm

30-37

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

k

30-38

Be sure to follow "Safety precautions to follow before starting work". 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 clearance between the axle and hole at the support 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

Steering system

Testing and adjusting steering oil pressure

Measurement condition 30-39 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". 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.

30-39

30-39

30-39 Adjusting k If the relief pressure is not correct, adjust the steering relief valve as follows. k When adjusting, stop the engine. 1. Loosen lock nut (6) of steering relief valve (2) and turn adjustment screw (7) to adjust the pressure. a Quantity of pressure adjustment per turn of adjustment screw Per turn: Approx. 3.5 MPa {Approx. 35.7 kg/cm2} a Turn the adjustment screw clockwise to increase 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 operating. 5. If [F3] switch is pressed while reading the oil pressure, the value is held. a If the hold [F3] switch is pressed again, the 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

a Testing tools
Symbol C 1 2 Part No. Part name

30-40

799-101-5002 Analog hydraulic tester 790-261-1204 Digital hydraulic tester 799-101-5160 Nipple

4. Remove oil pickup plug (5) (PT1/8) from between the diverter valve and the steering valve. Install nipple "C2" and oil pressure gauge "C1" (40 MPa {400 kg/cm2}).

Testing condition 30-40 q Hydraulic oil temperature: 45 to 50 C k Be sure to follow "Safety precautions to follow before starting work". k Loosen the oil filler cap to release the pressure 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 transmission end. 2. Disconnect the propeller shaft between the transmission and rear axle at the transmission end. 3. Disconnect diverter valve pilot hose (3), Replace elbow (4) with a pressure blocking elbow (see next page) and install hose (3). a This blocks oil pressure to the diverter valve pilot port and the system is put in the emergency steering mode.

5. Start the engine and shift to 3rd speed forward (or reverse). Increase the travel speed to 24 km/h on the speedometer, turn the steering wheel to the left or right, and measure the pressure when the relief valve is actuated.
k

Adjusting When adjusting, stop the engine. 1. Remove cap nut (6) of the relief valve.

30-40

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 adjustment screw Per turn: Approx. 3.5 MPa {Approx. 35.7 kg/cm2} a Turn the adjustment screw clockwise to increase the set pressure, and turn it counterclockwise 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

k

30-42
5. Run the engine at low idle. 1) Slowly move each cylinder to the right and left until they come to 100 mm before the stroke end. q Never let the relief valves actuate. q Steer alternately to right and left four or five times. 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.

Be sure to follow "Safety precautions to follow before starting work". a Bleed air from the circuit as follows if the steering valve or steering cylinder have been removed and installed. 1. Add oil to the hydraulic tank until the oil level reaches the upper limit G1 in the sight gauge.

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).

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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 level. Add oil as necessary until the level reaches the Full mark in the sight gauge.

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30-43

Steering system Testing and adjusting steering stopper bolt

Testing and adjusting steering stopper bolt

k

30-4

Be sure to follow "Safety precautions to follow before starting work".

3) When clearance adjustment is complete, 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 following procedure. a Clearance (a): 37 to 40 mm

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, slowly 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 oblong hole.

30-44

WA1200-6

Steering system Adjusting steering follow-up linkage

Adjusting steering follow-up linkage

k

30-45
3. In this condition, measure the voltage at frame angle potentiometer (2) and lever angle potentiometer (4). a Potentiometer voltage at neutral: 2.5 0.3 V 4. If the voltage is not 2.5 0.3 V, loosen mounting 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".

Be sure to follow "Safety precautions to follow before starting work".

30-45 Adjusting 1. Place the frame lock bar to the "LOCK" position and set the machine in the straight travel position.

2. Adjust length "L" of steering follow up linkage (1) to the specified length. a Specified length L: 342 mm

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30-45

Steering system Adjusting steering follow-up linkage

Adjusting installed position of potentiometer 30-46 (work in pair) a The installed position of the potentiometer can be adjusted while watching the multi monitor display screen. 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".

3. Check the value of the "AJSS lever potentiometer voltage" or "Frame potentiometer voltage" under the "Work equipment (controller)" and adjust the installed position of the potentiometer to achieve the standard range.

2. Select "Work equipment (controller)" on the "Rear-time monitor" display screen and press the "F6" switch. Then, the AJSS item detailed screen appears.

a Lever angle potentiometer adjustment procedure 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. 1) Note that the harness connectors of the lever 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 Adjusting steering follow-up linkage

Offset angle automatic correction procedure for 30-47 lever angle and frame angle potentiometers 1. Display the "SERVICE MENU SELECT" o "Adjustment menu" o "AJSS" o "AJSS Neutral Position Adjustment" on the multi monitor.

Machine position Frame angle voltage Lever angle voltage

Leftmost position 0.7 0.3 4.3 0.3

Unit: V (voltage) Rightmost NEUTRAL position 2.5 0.3 2.5 0.3 4.3 0.3 0.7 0.3

2. Place the machine body and the AJSS lever in the straight-ahead position.

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30-47

Steering system Adjusting steering follow-up linkage

3. Operate the machine body as instructed on the screen and press "F6". This sends a set signal to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway Pressing "F6" sends a set 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 equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. If the "F1" switch is pressed, the screen returns to the adjustment menu (2) AJSS screen.

4. Pressing "F6" displays the adjustment current value according to the information from the work equipment controller. "---" is displayed until information is notified for the first time after the screen appears. Pressing "F3" sends 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 equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. Pressing "F4" sends a DOWN signal to the work equipment controller.

5. Pressing "F6" displays the table pattern number according to the information from the work equipment controller. "-" is displayed until information is notified for the first time after the screen appears. Pressing "F6" sends an AJSS oil pressure command table pattern change signal to the work equipment controller. After the transmission of the signal, the pattern number is updated according to a signal from the work equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. If the "F1" switch is pressed, the screen returns to the adjustment menu (2) AJSS screen.

30-48

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Steering system Adjusting steering follow-up linkage

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

a Testing tools
Symbol C
k

30-50

Part No.

Part name

1 5

799-101-5002 Analog hydraulic tester 790-261-1204 Digital hydraulic tester 799-203-2440 Nipple

Be sure to follow "Safety precautions to follow before starting work".

30-50 Testing Lock the front frame and rear frame by using frame lock bars and chock the wheels to prevent 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 pressure in the piping.
k

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 lever steered) 0.49 to 0.64 MPa {4.8 to 6.3 kg/cm2})

30-50

WA1200-6

Steering system Testing steering EPC valve

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30-51

Steering system Testing and adjusting steering surge cut valve oil pressure

Testing and adjusting steering surge cut valve oil pressure

a Testing tools
Symbol 1 C Part No. 799-101-5002 Part name Oil pressure gauge kit (analog) (Pressure gauge: 60 MPa {600 kg/cm2}) Oil pressure gauge kit (digital) q Nipple Nipple

30-52

790-261-1204 2 799-101-5160 5 799-203-2440

Testing condition 30-52 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Lock the front frame and rear frame by using frame lock bars. k Loosen the oil filler cap of the hydraulic tank to release the pressure inside the hydraulic tank, then operate the steering lever two or three times to release the remaining pressure in the piping. a The procedure is common for both sides except for the location of the hydraulic pressure measuring points. a An oil pressure sensor (2) is installed on the left steering valve. 30-52 Testing 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 pressures are merged at the outlet side of the steering valve, right and left pressures cannot be measured separately at the outlet side. 1) When measuring the left steering valve oil pressure, remove steering oil pressure sensor (2) from tube (1) between the steering pump and steering valve, install nipples C5 and C2, and then install oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2) When measuring the right steering valve oil pressure, remove plug (4) from tube (3) between the steering pump and steering valve, install nipples C5 and C2, and then connect oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2. Loosen lock nut (6) on steering main relief valve (5), and screw in the adjustment screw (7) half a turn. a Ensure that only surge cut valve (8) is allowed to operate. q Steering main relief valve set pressure: 31.0 to 31.9 MPa {316 to 325 kg/cm2} q Surge cut valve set pressure: 33.3 to 34.3 MPa {340 to 350 kg/cm2}

30-52

WA1200-6

Steering system Testing and adjusting steering surge cut valve oil pressure

30-53 Adjusting a If the surge cut valve (8) set pressure is not correct, adjust following the steps below.

3. Start and run the engine at low idle (650 rpm). 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.

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 pressure. a Turn the adjustment screw clockwise to increase the set pressure, and turn it counterclockwise to decrease the pressure. a Pressure adjustment per one turn of adjustment 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, adjust the main relief valve. a After testing, bleed air from the circuit and check the oil level.

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30-53

Steering system Testing and adjusting steering main relief valve oil pressure

Testing and adjusting steering main relief valve oil pressure

a Testing tools
Symbol 1 C Part No. 799-101-5002 Part name Oil pressure gauge kit (analog) (pressure gauge: 60 MPa {600 kg/cm2}) Oil pressure gauge kit (digital) q Nipple Nipple

30-54

790-261-1204 2 799-101-5160 5 799-203-2440

Measurement condition 30-54 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Lock the front frame and rear frame by using frame lock bars. k Loosen the oil filler cap of the hydraulic tank to release the pressure inside the hydraulic tank, then operate the steering lever two or three times to release the remaining pressure in the piping. a The procedure is common for both sides except for the location of the hydraulic pressure measuring points. 30-54 Checking 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 pressures are merged at the outlet side of the steering valve, right and left pressures cannot be measured separately at the outlet side. 1) When measuring the left steering valve oil pressure, remove steering oil pressure sensor (2) from tube (1) between the steering pump and steering valve, install nipples C5 and C2, and then install oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2) When measuring the right steering valve oil pressure, remove plug (4) from tube (3) between the steering pump and steering valve, install nipples C5 and C2, and then install oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2. Start the engine and run at high idle (engine speed: 2,050 rpm). Measure the oil pressure when the steering lever is moved to the right or left and the main relief valve is actuated. q Main relief valve set pressure: 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.

Stop the engine before adjusting the main relief valve.

1. Loosen lock nut (6) of the main relief valve and turn adjustment screw (7) to adjust the pressure. a Turn the adjustment screw clockwise to increase the set pressure and turn it counterclockwise to decrease the pressure. a Pressure adjustment per one turn of adjustment screw Per turn: Approx. 17.8 MPa {Approx. 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 accurately.

WA1200-6

30-55

Steering system Testing rotary valve output pressure

Testing rotary valve output pressure

a Testing tools
Symbol C 1 7 Part name Oil pressure gauge kit (ana799-101-5002 log) 790-261-1204 Oil pressure gauge kit (digital) 790-261-1331 q Adapter Part No.

30-56

30-56 Testing condition q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Lock the front frame and rear frame by using frame lock bars.

Loosen the oil filler cap of the hydraulic tank to release the pressure inside the hydraulic tank, then operate the steering lever two or three times to release the remaining pressure in the piping.

2. Install oil pressure gauge C1 to adapter C7. 3. Start and run the engine at low idle, and then slowly move steering lever (7) to the right and left stroke ends. 4. While holding steering lever (7), raise the engine speed to high idle.

30-56 Testing 1. To test the rotary valve output pressure, install adapter C7 between hose (2) and nipple (3) that 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 P4 at both ends of the steering valve, and calculate the difference.
q q

a Rotary valve output pressure difference standard value

Conditions Hydraulic oil temperature: 45 to 55 C Engine at high idle Standard value 3.53 to 4.11 MPa {36 to 42 kg/cm2}

Relationship between hydraulic system diagram and oil pressure at each part

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30-57

Brake system Testing brake performance

Brake system

Testing brake performance

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

30-58

30-58

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 starting 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

a Testing tools
Symbol I
k k

30-59

Part No. Part name 793-520-1805 Brake test kit 793-520-1851 q Nipple

Be sure to follow "Safety precautions to follow before starting work". 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

a Testing tools
Symbol C 1 Part name Oil pressure gauge kit (ana799-101-5002 log) 790-261-1204 Oil pressure gauge kit (digital) Part No.

30-60
4. Then, read the maximum pressure (relief pressure) while holding down the brake pedal. a Slack adjuster operating pressure standard value
Check item Check valve operating pressure (cracking pressure) Maximum pressure (relief pressure) Standard value 1.69 to 1.79 MPa {17.3 to 18.3 kg/cm2} 17.3 to 17.9 MPa {177 to 183 kg/cm2}

30-60 Testing condition q Brake oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Chock the wheels to prevent the machine from moving. 30-60 Checking 1. Release the remaining pressure in the brake circuit at bleeder (2) of slack adjuster (1). 2. Remove plug (3) and install oil pressure gauge C1.

a Check also plug (4) same as described above. a Check both the front side and rear side of the slack adjuster.

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

k k

30-61

Be sure to follow "Safety precautions to follow before starting work". 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

k

30-62

Be sure to follow "Safety precautions to follow before starting work".

30-62 Measurement Brake oil temperature: 45 to 55 C k Stop the engine, then depress the brake pedal at least 100 times to release the pressure inside the accumulator circuit. 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. 3. Display item "F brake pressure" or "R brake pressure" (page 4/4 of "PM-CLINIC MENU" screen).
q

4. Measure the accumulator charge cut-out pressure. Measure the oil pressure when the rising oil pressure alters to drop. Cut-out pressure: 20.6 to 22.1 MPa {210 to 225 kg/cm2} 5. Measure the accumulator charge cut-in pressure. Start the engine and run at low idle. While observing the pressure fall, measure the minimum pressure when the oil pressure gradually alters from fall to rise (read the F brake pressure or R brake pressure on the multi monitor). Cut-in pressure: 17.6 to 18.2 MPa {180 to 186 kg/cm2} 6. If [F3] switch is pressed while reading the oil pressure, the value is held. a If the hold [F3] switch is pressed again, the 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 provided. 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 increased. 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.

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30-63

Brake system Testing brake accumulator oil pressure leakage

Testing brake accumulator oil pressure leakage

k k

30-64

Be sure to follow "Safety precautions to follow before starting work". Lock the front frame and rear frame by using frame lock bars.

4. Disconnect hose (3) between tube (2) of emergency parking brake valve (1) and the accumulator.

30-64 Testing Start and run the engine until the charge pressure 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 } 2 q Used machine: 20.6 MPa {210 kg/cm } a Check the charge pressure at "F brake oil pressure" or "R brake oil pressure" (page 4/4 of "PM-CLINIC MENU" screen) of the multi monitor.
q

5. Securely install plug (4) and O-ring (5) to disconnected 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 pressure" (page 4/4 of "PM-CLINIC MENU" 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 pressure.

30-64

WA1200-6

Brake system Testing brake accumulator oil pressure leakage

6. Start and run the engine until the charge pressure 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 } 2 q Used machine: 20.6 MPa {210 kg/cm } 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 remove the remaining pressure. 8. Reconnect hose (3) to tube (2). 9. If the pressure dropped below 14.7 MPa {150 kg/cm2}, check for leaks from the emergency parking brake valve.

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30-65

Brake system Testing emergency parking brake valve oil leakage amount

Testing emergency parking brake valve oil leakage amount

k k

30-6

Be sure to follow "Safety precautions to follow before starting work". 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.

Releasing remaining pressure from the brake 30-6 accumulator 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 pressure" (page 4/4 of "PM-CLINIC MENU" screen).

30-6 Preparation a Prepare an oil container to collect the brake oil flowing out and a measuring cylinder. 1. Disconnect return hose (2) of emergency parking brake valve (1) from tube (3), and install sleeve nut and plug [1] to tube (3). q [1] Part number: 07221-20422 Sleeve nut : 07222-00414 Plug a Place an oil container to collect the brake oil flowing out.

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 pressure.

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 Testing emergency parking brake valve oil leakage amount

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).

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30-67

Brake system Testing emergency parking brake valve oil leakage amount

30-68

WA1200-6

Brake system Testing brake valve oil leakage amount

Testing brake valve oil leakage amount

k k

30-69

Be sure to follow "Safety precautions to follow before starting work". Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. chock the wheels to prevent the machine from moving.

30-69 Preparation q Prepare an oil container to collect the brake oil flowing out and a measuring cylinder. Measuring left brake valve (single) oil leakage 30-69 amount 1. Disconnect drain hose (2) of left brake valve (1) at elbow (4) side of tube (3). a Place an oil container to collect the brake oil flowing out.

Releasing remaining pressure from the brake 30-69 accumulator 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 pressure" (page 4/4 of "PM-CLINIC MENU 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 pressure.

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

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30-69

Brake system Testing brake valve oil leakage amount

3. 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. k Never depress the brake pedal. q Accumulator charge valve cut-out pressure: 20.6 to 22.1 MPa {210 to 225 kg/cm2} 4. Collect the brake oil that flows out from the disconnected drain hose (2) in a measuring cylinder [2] and check the amount of leakage during 1 minute. 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 New brake valve: 105 cc/minute q Brake valve replacement standard: Min. 160 cc/minute

Measuring right brake valve (tandem) oil leakage 30-70 amount 1. Stop the engine. 2. Disconnect tube (3) from the drain port of right brake valve (5). a Place an oil container to collect the brake oil flowing out. a Remove hose (2) without disconnecting it from tube (3). a Leave elbow (6) and connector (7) on right brake valve (5).

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 standard, replace the left brake valve assembly or seals.

4. 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}

30-70

WA1200-6

Brake system Testing brake valve oil leakage amount

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 > q New brake valve: 85 cc/minute q Brake valve replacement standard: Min. 128 cc/minute Reference < brake oil temperature: 80 C > q New brake valve: 213 cc/minute q Brake valve replacement standard: Min. 320 cc/minute

6. If the leakage exceeds the replacement standard, replace the right brake valve assembly or seals.

WA1200-6

30-71

Brake system Testing brake valve oil leakage amount

Brake hydraulic circuit diagram

30-72

30-72

WA1200-6

Brake system Testing brake valve oil leakage amount

WA1200-6

30-73

Brake system Testing brake cooling oil pressure

Testing brake cooling oil pressure

a Testing tools
Symbol Part name Oil pressure gauge kit (analog) 799-101-5002 (pressure gauge: 2.5 MPa 1 {25 kg/cm2}) 790-261-1204 Oil pressure gauge kit (digital) 3 790-301-1271 q Joint Part No.

30-74

Testing condition 30-74 q Engine speed: High idle (2,050 rpm) q Brake cooling oil temperature: 80 C k Be sure to follow "Safety precautions to follow before starting work". 1. Preparation q In order to test the brake cooling oil pressure, remove tubes (3) and (4) from blocks (1) and (2). Drill and tap oil pressure pickup holes (10 mm dia., thread pitch 1.25 mm) at portion "B" of tubes (3) and (4). a Part number of plug installed to tapped hole: 07040-11007: Plug 07002-21023: O-ring 2. Testing 1) Stop the engine. k Loosen the brake oil tank cap to release the pressure inside the tank. 2) Remove two plugs from the drilled and tapped holes (M10 P1.25) and install joints C3 to each hole. Connect oil pressure gauges C1 (2.5 MPa {25 kg/cm2}) to joints C3. 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 value: 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 value: 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 performance

a Testing tools
Symbol B Part No. 799-101-1502 Part name Digital thermometer kit

30-76

Testing parking brake performance

30-76

a Test the parking brake performance under the following conditions.

q q q

Be sure to follow "Safety precautions to follow before starting work".

Tire inflation pressure: Specified pressure Road: 1/5 gradient (11 deg. 20'), flat, and dry road Machine: Ready for operation

a To test the brake oil cooler performance, measure the temperature at the inlet and outlet of the brake oil cooler and calculate the difference. 1. Stop the engine. 2. Remove plugs (4) from tubes (1) and (2) at their brake oil cooler (3) side, and install oil temperature gauges to two places.

1. Start the engine and set the machine in the straight travel position, and then drive up a slope of 1/5 gradient with no load in the bucket.

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 release the brake gradually. At this time, the machine must not move. a Measure the parking brake performance on an uphill and a downhill.

3. Start the engine and check the temperature difference between the brake oil cooler inlet and outlet. a Temperature difference: 14 C 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

a If the parking brake does not work effectively, check the parking brake disc for wear according to the following procedure. k Be sure to follow "Safety precautions to follow before starting work". 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).

30-7
5. If the parking brake disc (5) thickness is below the standard value, replace the disc. q Standard depth (a): Max. 46.3 mm q Repair limit depth (reference value): Max. 51.6 mm

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

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30-77

Brake system Method of releasing parking brake manually

Method of releasing parking brake manually

a The parking brake is controlled hydraulically. If 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 Be sure to follow "Safety precautions to follow before starting work". k Releasing the parking brake manually is a means to move the machine from a dangerous 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. 1. Drain oil from the transmission case. 6 Transmission case approx. 350 l 2. Remove 2 plugs (1).
q q

30-78

Set of 16 discs

Refilling Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.

3. Remove two cage mounting bolts (2), and tighten them alternately in plug installation positions. 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

Testing parking brake inlet pressure a Testing tools
Symbol C 1 3 Part No. Part name

30-79
a Parking brake solenoid inlet pressure standard value
q q

30-79

799-101-5002 Analog hydraulic tester 790-261-1204 Digital hydraulic tester 790-301-1271 Joint

Conditions Standard value Torque converter oil temperature: 2.45 to 2.85 MPa 60 to 80 C {25 to 29 kg/cm2} Engine speed: At high idle

a Torque converter oil temperature: 60 to 80 C k Be sure to follow "Safety precautions to follow before starting work". k Chock the wheels to prevent the machine 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 q

Conditions Standard value Torque converter oil temperature: 2.45 to 2.85 MPa 60 to 80 C {25 to 29 kg/cm2} Engine speed: At high idle

Testing parking brake solenoid inlet pressure 30-79 a Testing tools

Symbol C 1 4 Part No. Part name

799-101-5002 Analog hydraulic tester 790-261-1204 Digital hydraulic tester 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 pedal 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.

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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
Symbol Part No. Part name Applicable standard For old type ACC For old and new type ACC GOST CGA No.351 ASA B-571-1965 DIN 477-1963 NEN32681966 SIS-SMS 2235/2238 BS 341 Part1-1962 792-610-1701 Gas charge tool kit 792-610-1700 q Gas charge tool 07000-11009 q O-ring 1 792-610-1702 Gas charge tool kit 792-610-1700 q Gas charge tool 07000-11009 q O-ring 792-610-2310 q Extension Nipple 792-610-1310 (For Russia) Nipple 792-610-1320 R (For USA) Nipple 792-610-1330 2 (For USA) 792-610-1350 Nipple (For Germany) Nipple (For UK)

792-610-1360
k k

Precautions when connecting the gas charge 30-80 tool R1 1. Sealant has been applied to the threaded portion of the adapter (5) for the gas charge tool R1. Never attempt to remove it unless absolutely necessary. Otherwise, the gas may leak out. 2. On some gas valves (4), the length of the threads (B) may be not long enough for the depth (A) from the end face of the adapter (5) to the packing (6) of the gas charge tool R1, preventing the gas valve (4) from seating completely. In such a case, nitrogen gas may leak out through the threads of the gas valve (4). 3. When connecting the gas charge tool R1 to the gas valve (4) but the extension (P/N: 792-610-2310) supplied with the tool is not available, install O-ring (7) (P/N: 07000-11009) supplied with the tool to gas valve (4). Connect the gas charge tool R1. Then, check to ensure that there is no leakage.

Be sure to follow "Safety precautions to follow before starting work". 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. When handling nitrogen gas in a room or another place which is not ventilated well, ventilate the work place forcibly and observe the Oxygen Deficiency Prevention Rules of the Labor Safety and Sanitation Law. The accumulator is charged with high-pressure 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 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 observe the precautions given in this manual.

4. If extension (8) (P/N: 792-610-2310) supplied with the tool is available, install extension (8) to gas valve (4) and then connect gas charge tool R1. a The O-ring supplied with the tool will not be used.

30-80

WA1200-6

Brake system Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas

Testing nitrogen gas pressure in accumulator 30-81 a The measuring is also possible on the accumulator alone. a Nitrogen gas cylinder (c) must be connected even when you measure only the gas pressure. 1. Stop the engine and depress the brake pedal repeatedly to lower the oil pressure in the brake circuit to zero. 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 accumulator (1). (Old type accumulator)

3) Install the extension (8) (P/N: 792-610-2310) supplied with the tool to the 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 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 Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas

5) Connect gas charge tool R1 to nitrogen gas cylinder (c). a Avoid applying bending load to the gas valve (4), which may otherwise break. a There are 2 types of threads of nitrogen gas cylinders, W23-14 thread (mail screw, type A) and W23-14 thread (female screw, type B). When using a gas cylinder of W23-14 thread (female screw, type B), connect the hose by using the adapter. (The adapter is supplied with the gas charge tool R1.) 5. Slowly turn clockwise handle (a) of gas charge tool R1 and read the gauge. a Since the indicated value varies with the ambient 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 temperature C 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Gas pressure MPa kg/cm2 4.34 44.2 4.35 44.4 4.37 44.5 4.38 44.7 4.40 44.8 4.41 4.43 4.44 4.46 4.47 4.49 4.50 4.52 4.53 4.55 4.56 4.58 4.59 4.61 4.62 4.64 4.65 4.67 4.68 4.70 4.71 4.73 4.74 4.76 4.77 4.79 45.0 45.2 45.3 45.5 45.6 45.8 45.9 46.1 46.2 46.4 46.5 46.7 46.8 47.0 47.2 47.3 47.5 47.6 47.8 47.9 48.1 48.2 48.4 48.5 48.7 48.8 Remarks

6. If the gas pressure is too high or too low, adjust it referring to "Procedure for charging accumulator 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 the charge tool R1 fully counterclockwise. 8. Remove gas charge tool R1 from accumulator (1) and restore the machine. Refer to "Procedure for charging accumulator with nitrogen gas".

Standard gas pressure

t: Gas temperature when charging ( C) Reference: t may be assumed to be ambient temperature.

30-82

WA1200-6

Brake system Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas

Procedure for charging accumulator with nitro30-83 gen gas a The accumulator can also be charged in a similar 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. 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 accumulator (1). (Old type accumulator)

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 depending on the specification of the nitrogen gas cylinder. 3. Remove plug (9) from accumulator (1). (New type accumulator)

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 Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas

5. Slightly open the valve on the nitrogen gas cylinder (c) to discharge nitrogen gas at a pressure of approx. 0.19 to 0.29 MPa {2 to 3 kg/cm2}. 6. After nitrogen gas starts flowing out of handle (b), close handle (b) by turning it to the right. 7. Turn handle (a) slowly to the right to open valve (4) of accumulator (1) gradually. a If handle (a) is turned too much, the valve core of the accumulator will be damaged and gas will leak. Accordingly, operate handle (a) carefully. 8. Open the valve of nitrogen gas cylinder (c) further to charge the accumulator with nitrogen gas. 9. During the work, close the valve of nitrogen gas cylinder (c) and check the nitrogen gas pressure in the accumulator. a Since the indicated value varies with the ambient 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)) Quick reference table for gas pressure in the accumulator
Ambient temperature C 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Gas pressure MPa kg/cm2 4.34 44.2 4.35 44.4 4.37 44.5 4.38 44.7 4.40 44.8 4.41 4.43 4.44 4.46 4.47 4.49 4.50 4.52 4.53 4.55 4.56 4.58 4.59 4.61 4.62 4.64 4.65 4.67 4.68 4.70 4.71 4.73 4.74 4.76 4.77 4.79 45.0 45.2 45.3 45.5 45.6 45.8 45.9 46.1 46.2 46.4 46.5 46.7 46.8 47.0 47.2 47.3 47.5 47.6 47.8 47.9 48.1 48.2 48.4 48.5 48.7 48.8 Remarks

t: Gas temperature when charging ( C) Reference: t may be assumed to be ambient temperature. 10. After the accumulator is charged to the standard pressure, close the valve of nitrogen gas cylinder (c). q If the accumulator is charged too much, turn handle (b) to the left slowly with the valve of nitrogen gas cylinder (c) closed to release the nitrogen gas gradually to adjust. 11. Remove gas charge tool R1 from gas valve (4) of accumulator (1) according to the following procedure. 1) Turn handle (a) to the left to close the valve of the accumulator. 2) Turn handle (b) to the left to open and discharge nitrogen gas remaining in gas charge tool R1 and hoses. 3) Remove gas charge tool R1 from gas valve (4) on the accumulator. 4) Remove extension (8) from gas valve (4). Alternatively, remove O-ring (7) from gas valve (4). 12. Apply soap water to gas valve (4) of the accumulator to ensure that nitrogen gas is not leaking. 13. Install plug (9) to accumulator (1). 3 Plug: 73.5 to 98.0 Nm {7.5 to 10.0 kgm}

Standard gas pressure

30-84

WA1200-6

Brake system Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas

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 stopping 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" position. 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

Hydraulic system
q

Testing and adjusting work equipment oil pressure by using multi monitor
k

30-86
30-86

Hydraulic oil temperature: 45 to 55 C Be sure to follow "Safety precautions to follow before starting work".

3) Press F6 on an item in "Work equipment" to display "Pressure at the moment". 4) Start the engine, slowly raise the lift arm to the stroke end, and then perform a lift arm raise operation with the engine running at full speed. Read the oil pressure when the relief valve actuates on the "Pressure at the moment" screen.

30-86 Checking 1. Measurement of work equipment relief pressure 1) Select "SERVICE MENU SELECT" on the multi monitor screen.

2) Use item selection switches F3 and F4 to select Real-time monitor, and then press F6 switch to display the "Real-time monitor" screen.

2. If [F3] switch is pressed while reading the oil pressure, the value is held. a If the hold [F3] switch is pressed again, the 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 "Troubleshooting of work equipment oil pressure (20-1001-4158)". 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.

a If the adjustment screw is q Turned clockwise, the pressure is increased. q Turned counterclockwise, the pressure 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.

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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
Symbol C 1 Part No. Part name

799-101-5002 Analog hydraulic tester 790-261-1204 Digital hydraulic tester

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. q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Stop the engine, then loosen the oil filler cap to release the pressure in the hydraulic tank. a For the layout drawing, see 20-136-6 to 20-136-7-2. 30-8 Testing 1. Remove the oil pressure pickup plug corresponding 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) q No. 2 control valve (work equipment pump No. 1 front pump side): 1A (thread size: M10 x 1.25)

q q

No. 3 control valve (switch pump rear pump side): 3B (thread size: M10 x 1.25) No. 3 control valve (switch pump front pump side): 3A (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 (20-1001-4158)", test oil pressures to check if the pumps and valves are normal. 30-8 Adjusting a For the adjustment procedures, see "Testing and adjusting work equipment oil pressure by using the multi monitor".
q

No. 1 control valve (work equipment pump No. 2 rear pump side): 2B (thread size: M10 x 1.25) No. 2 control valve (work equipment pump 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

q k k k

30-89

Hydraulic oil temperature: 45 to 55 C Be sure to follow "Safety precautions to follow before starting work". Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Operate the work equipment control lever two to three times to release the pressure from the PPC accumulator circuit.

5) If [F3] switch is pressed while reading the oil pressure, the value is held. a If the hold [F3] switch is pressed again, the value is released. 2. Measuring PPC pressure difference between both ends of main valve 1) Remove the work equipment valve cover. 2) Remove oil pressure pickup plugs (M20x1.5) (1) to (4) for each circuit and install nipples C3-1, C2 and oil pressure gauge C1 (6 MPa {60 kg/cm2}).
k

30-89 Measurement 1. Measuring PPC relief pressure 1) Select "Service Menu" on the multi monitor screen.

1. For lift arm RAISE 3. For bucket DUMP 2. For lift arm LOWER 4. For bucket CURL

Since the PPC circuit has been disassembled 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} 2) Use item selection switches F3 and F4 to select Pm Clinic, and then press F6 switch to display the "PM-CLINIC MENU" screen. 3) Display item "PPC oil pressure" (page 4/4 of "PM-CLINIC MENU" screen).

4) Start the engine and measure the oil pressure with the engine running at full speed.

WA1200-6

30-89

Hydraulic system Testing and adjusting work equipment PPC oil pressure

30-90 Adjusting 1. Adjusting PPC relief valve k Stop the engine before adjusting the adjustment screw. 1) Remove the cover at the top of the transmission. 2) Loosen lock nut (6) of PPC relief valve (5), then turn adjustment screw (7) to adjust. a If the adjustment screw is q Turned clockwise, the pressure is increased. q Turned counterclockwise, the pressure is decreased. a Quantity of pressure adjustment per turn of adjustment screw: 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 possibility that the set pressure is too high. Therefore, raise the engine speed gradually to avoid generation of abnormal pressures in the circuit. 4) If the set pressure does not reach the specified 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

a Oil pressure measuring points are shown in the drawing below.

30-91

WA1200-6

30-91

Hydraulic system Measuring point of hydraulic pump oil pressure

a Oil pressure measuring points are shown in the drawing below.

30-92

WA1200-6

Hydraulic system Measuring point of hydraulic pump oil pressure

Work equipment pump line a Hydraulic piping are shown in the drawing below.

30-93

WA1200-6

30-93

Hydraulic system Measuring point of hydraulic pump oil pressure

Switch pump, steering pump lines a Hydraulic piping are shown in the drawing below.

30-94

30-94

WA1200-6

Hydraulic system Testing and adjusting PV control relief valve oil pressure

Testing and adjusting PV control relief valve oil pressure

a Testing tools
Symbol Part name Oil pressure gauge kit (analog) 799-101-5002 (pressure gauge: 6 MPa 1 {60 kg/cm2}) 790-261-1204 Oil pressure gauge kit (digital) 2 799-101-5160 q Nipple Part No.

30-95

Testing condition 30-95 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine 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 equipment pump. PV valve set pressure: 2.9 MPa {30 kg/cm2}

Testing 30-95 1. Stop the engine. k Operate the work equipment control lever to release the pressure from the work equipment PPC accumulator. 2. Remove plug (2) (PT1/8) from block (1), install nipple C2, and then connect oil pressure gauge C1 (6 MPa {60 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

30-96 Adjusting 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 turn adjustment screw (5) to adjust the pressure. a Turn the adjustment screw clockwise to increase the set pressure, and turn it counterclockwise to decrease the pressure. a Pressure adjustment per one turn of adjustment 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

a Testing tools
Symbol 1 C Part No. 799-101-5002 Part name Oil pressure gauge kit (analog) (Pressure gauge: 6 MPa {60 kg/cm2}) Oil pressure gauge kit (digital) q Nipple q Adapter

30-97

790-261-1204 2 799-101-5160 4 799-261-1311

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.

Testing condition 30-97 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Stop the engine, then loosen the oil filler cap to release the pressure in the hydraulic tank.
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 equipment pump (2).

30-97 Testing 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 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 {60 kg/cm2}) to nipple C2.

C1

(6

MPa

30-98 Adjusting 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.
q

Standard values for pressure difference between P1 and P2 ports

Oil pressure (MPa {kg/cm2}) P1 port P2 port 3.7 to 3.9 {38 to 40} 4.3 to 4.9 {44 to 50} 3.7 to 3.9 {38 to 40} 4.9 to 5.5 {50 to 56} Differential pressure (MPa {kg/cm2}) 0 0.5 to 0.6 {5 to 6}

Engine speed Low idle (625 675 rpm) High idle (1,850 1,950 rpm)

3) Remove plug (7), and add or remove shims (8). a When adjusting by using shims for the differential valve, set it with the plug facing up. a Shim part No.: 427 - 62 - 11710 (t 0.1) : 427 - 62 - 11720 (t 0.2) : 427 - 62 - 11730 (t 0.5) 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).

30-98

WA1200-6

Hydraulic system Testing work pump ES valve output pressure

Testing work pump ES valve output pressure

a Testing tools
Symbol 1 C Part No. 799-101-5002 Part name Oil pressure gauge kit (analog) (pressure gauge: 6 MPa {60 kg/cm2}) Oil pressure gauge kit (digital) q Nipple q Adapter

30-9

790-261-1204 2 799-101-5160 4 799-261-1311

a Oil pressure enters the ES valve from the work equipment pump cut-off solenoid valve (3) port A to ES valve (1) port P1, and from differential pressure valve (4) port PB to ES valve (1) port P2. The output pressure of the ES valve is determined by the differential pressure between port P1 and port P2.

Testing condition 30-9 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Stop the engine, then loosen the oil filler cap to release the pressure in the hydraulic tank. a Work equipment pump ES valve (1) is installed to No. 2 work equipment pump (2).

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30-99

Hydraulic system Testing work pump ES valve output pressure

30-10 Testing a Install pressure gauges to ports P1 and P2 of the 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 {60 kg/cm2}) to nipple C2.

ES valve output pressure standard value: 1.8 MPa {18.34 kg/cm2}

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 standard 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

a Testing tools
Symbol 1 C 2 3 4 Part No. 799-101-5002 790-261-1204 799-101-5160 790-301-1271 790-261-1311 Part name Oil pressure gauge kit (analog) (Pressure gauge: 40 MPa {400 kg/cm2}) Oil pressure gauge kit (digital) q Nipple q Joint q Adapter

30-101

30-101 No. 1 work equipment pump 1. Preparation 1) Remove the rear side pump delivery pressure pickup plug (7) on the No. 1 work equipment pump. 2) Install joint C3 and nipple C2 of the oil pressure gauge kit, and connect oil pressure gauge C1 (40 MPa {400 kg/cm2}) to nipple C2.

30-101 Testing condition q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Stop the engine, then loosen the oil filler cap to release the pressure in the hydraulic tank. 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 work equipment pump (1) and No. 2 work equipment 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.

3) Remove step (1) from No. 1 work equipment pump (1).

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30-101

Hydraulic system Testing and adjusting work pump CO (cut-off) valve oil pressure

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 pressure 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 Testing and adjusting work pump CO (cut-off) valve oil pressure

3. Adjusting CO valve pressure 1) Adjust by loosening lock nut (10) for CO+NC valve (4) and turning adjustment screw (11) with a screwdriver. a To raise the cut-off, turn adjustment screw (11) clockwise. To lower the cut-off, turn it counterclockwise. Repeat the procedure until the correct set pressure 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}.

No. 2 work equipment pump 30-103 1. Preparation 1) Remove front pump delivery pressure pickup plug (11) from the No. 2 pump. 2) Install joint C3 and nipple C2 of the oil pressure gauge kit, and connect oil pressure gauge C1(40 MPa {400 kg/cm2}) to nipple C2.

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 {60 kg/cm2}) to nipple C2.

2) After adjustment is completed, remove the joint and nipple of the oil pressure gauge kit and restore the machine.

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30-103

Hydraulic system Testing and adjusting work pump CO (cut-off) valve oil pressure

2. Testing CO valve oil pressure 1) With the engine running at low idle (650 rpm) and the bucket slowly brought to TILT end, read the No.2 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})

3. Adjusting CO valve pressure 1) Adjust by loosening lock nut (16) for CO+NC valve (5) and turning adjustment screw (17) with a screwdriver. a To raise the cut-off, turn adjustment screw (17) clockwise. To lower the cut-off, turn it counterclockwise. Repeat the procedure until the correct set pressure is obtained. a Turning in the adjustment screw one turn will increase the No. 2 work equipment pump delivery pressure by 4.1 MPa {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. q CO valve output pressure standard value: 0.74 MPa {7.6 kg/cm2} a Increase the engine speed if the No. 2 work equipment pump delivery pressure does not reach 25.5 MPa {260 kg/cm2}.

2) After adjustment is completed, remove the 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
a Testing and adjusting tools for No. 2 work equipment pump
Symbol 1 N 2 3 4 Part No. 799-101-5002 790-261-1204 799-401-2701 799-101-5220 07002-11023 799-401-3200 Part name Hydraulic tester Digital hydraulic tester Differential pressure gauge Nipple (10 x 1.5 mm) O-ring Adapter (size: 03)

30-105

2) While running the engine at low idle (650 rpm), gradually move the pallet to tilt end and measure the TVC valve output pressure. 3) Install nipple N3 and connect it to oil pressure gauge [1] of hydraulic tester N1. a Use an oil pressure gauge with the capacity of 6 MPa {60 kg/cm2}.

30-105 Testing condition q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Stop the engine, then loosen the oil filler cap to release the pressure in the hydraulic tank. 1. Measuring TVC valve output pressure a Since the TVC valve output pressure varies with the delivery pressure of the pump, check that the oil pressure in the work equipment circuit is normal before starting measurement. a Since the source pressure of the TVC valve output pressure is the control circuit pressure, check that the control circuit pressure is normal before starting measurement. 1) Remove oil pressure pickup plug (1) of the No. 2 work equipment pump. 4) Gradually operate the lift arm lever of the work equipment and let the No. 2 work equipment pump delivery pressure increase. Measure the TVC valve output pressure. 5) After completing measurement, remove the measuring instruments and restore the machine. 2. Adjusting TVC valve a If the TVC valve output pressure is abnormal, adjust TVC valve (8) of the No. 2 work equipment pump according to the following procedure.

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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 pressure. a If the adjustment screw is q Turned clockwise, the pressure is increased. q Turned counterclockwise, the pressure is decreased. a Quantity of pressure adjustment per turn of adjustment screw: 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

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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)
a Testing tools
Symbol Part No. Part name Oil pressure gauge kit (analog) (Pressure gauge: 6 MPa {60 kg/cm2}), 40 MPa {400 kg/cm2} Oil pressure gauge kit (digital) q Nipple q Joint q Adapter q Plug (on PPC hose) q Sleeve nut (central block side) q Plug (central block side)

30-107

799-101-5002 790-261-1204 799-101-5160 790-301-1271 790-261-1311 07376-50315 07221-20315 07222-00312

C 2 3 4 9 10 11

30-107 Testing 1. Operate each individual work equipment valve to raise the boom, measure the time it takes for the boom to raise and determine whether the time is correct or too slow. 2. If the rising time is too slow, the corresponding valve is faulty (inoperative) or the hydraulic pump is faulty.

Testing condition 30-107 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". a If slow work equipment speed or other problems occur that appear attributable to the work equipment hydraulic system but it is not possible to determine which device(s) is the cause(s), troubleshoot by following the steps below.

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30-107

Hydraulic system Operation test of work equipment valve by work equipment speed (speed of work equipment is low)

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) Valve No. No. 1 (left) No. 2 (center) No. 3 (right) Time (sec) When normal Q Q Q 12 14 Condition 1 Q 41 44 Q: Valve operated -: Valve not operated Rising time too slow Condition 2 Condition 3 Q Q 33 35 41 44 Q: Valve operated -: Valve not operated Rising time too slow Condition 2 Condition 3 Q Q 58 61 205 208 Q: Valve operated -: Valve not operated Condition 2 Condition 3 Q Q 650 522 Q: Valve operated -: Valve not operated Condition 2 Condition 3 Q Q 370 107

2) Engine at low idle (625 675 rpm) Valve No. No. 1 (left) No. 2 (center) No. 3 (right) Time (sec) When normal Q Q Q 36 39 Condition 1 Q 205 208

4. Individual valve delivery (reference)

1) Max. pump swash plate angle Valve No. When normal No. 1 (left) Q No. 2 (center) Q No. 3 (right) Q Delivery (l/min) 1,694 2) Min. pump swash plate angle Valve No. When normal No. 1 (left) Q No. 2 (center) Q No. 3 (right) Q Delivery (l/min) 584 Condition 1 Q 522 Condition 1 Q 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 Valve No. Front (F) Rear (R) Front (F) Rear (R) No. 1 (left) 325 197 No. 2 (center) 325 197 No. 3 (right) Switching pump Front (F) Rear (R) 325 325 Delivery (l/min) 522 522 650

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 Valve No. Front (F) Rear (R) Front (F) Rear (R) No. 1 (left) 45 62 No. 2 (center) 45 62 No. 3 (right) 3) Boom cylinder swept volume Stroke Swept volume (mm) (2 cylinders)(l) 1,812 368.9 Switching pump Front (F) Rear (R) 45 325 Delivery (l/min) 107 107 370

30-108

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Hydraulic system Operation test of work equipment valve by work equipment speed (speed of work equipment is low)

Check 30-109 a If the work equipment speed is too low, the faulty (inoperative) valve can be identified by operating that valve to measure the boom rising time while closing the boom PPC pilot ports (both for lowering and raising) for all other valves to prevent the relevant boom spools from being actuated. a There is a valve on which the main relief valve pressure is not set to the standard value. q Main relief valve operating pressure: 31.4 MPa {320 kg/cm2} 1) With the circuits (for both tilting and dumping) closed other than the one for the bucket pilot circuit on one of the No. 1, No. 2 and No. 3 valves, tilt the bucket while noting the pressure at which the relief valve is actuated. a Check the relief valve operating pressure in "Testing and adjusting work equipment oil pressure". a If the relief valve set pressure reading agrees with the standard value, the valve with the closed circuits is incorrectly adjusted. k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Operate the work equipment control lever two to three times to release pressure from the PPC accumulator circuit.

No. 1 valve (boom spool) q Disconnect PPC hoses (3) and (4) from blocks (1) and (2). Correctly install plug C9, sleeve nut C10 and plug C11 to the blocks and PPC hoses. No. 2 valve (boom spool) q Disconnect PPC hoses (5) and (6) from blocks (1) and (2). Correctly install plug C9, sleeve nut C10 and plug C11 to the blocks and PPC hoses. No. 3 valve (boom spool) q Disconnect PPC hoses (7) and (8) from blocks (1) and (2). Correctly install plug C9, sleeve nut C10 and plug C11 to the blocks and PPC hoses. No. 1 valve (bucket spool) q Disconnect PPC hoses (9) and (10) from blocks (1) and (2). Correctly install plug C9, sleeve nut C10 and plug C11 to the blocks and PPC hoses. No. 2 valve (bucket spool) q Disconnect PPC hoses (11) and (12) from the blocks (1) and (2). Correctly install plug C9, sleeve nut C10 and plug C11 to the blocks and PPC hoses. No. 3 valve (bucket spool) Disconnect PPC hose (15) from nipple (14) on tube (13). 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.
q

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30-109

Hydraulic system Operation test of work equipment valve by work equipment speed (speed of work equipment is low)

30-110

WA1200-6

Hydraulic system Operation test of work equipment valve by work equipment speed (speed of work equipment is low)

Schematic of valves and pilot lines

30-1 1

WA1200-6

30-111

Hydraulic system Operation test of work equipment valve by work equipment speed (speed of work equipment is low)

[Reference] PPC output circuit

30-112

WA1200-6

Hydraulic system Operation test of work equipment valve by work equipment speed (speed of work equipment is low)

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30-113

Hydraulic system Testing hydraulic oil cooler performance

Testing hydraulic oil cooler performance

(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 k Be sure to follow "Safety precautions to follow before starting work". 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

30-1 4

Aim a temperature gun to inlet tube (4) and outlet tube (5) to measure the temperature and calculate the difference. a Temperature difference standard value: 11 to 13 C

30-114

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Hydraulic system Testing hydraulic oil cooler performance

(Testing by oil pressure measurement) a Testing tools

Symbol Part No. Part name B 799-101-1502 Digital thermometer kit Oil pressure gauge kit (analog) 799-101-5002 (pressure gauge: 2.5 MPa 1 C {25 kg/cm2}) 790-261-1204 Oil pressure gauge kit (digital) 3 790-301-1271 q Joint

30-1 5

Be sure to follow "Safety precautions to follow before starting work". 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 pressure and oil temperature characteristics, judge the good/bad of the cold relief valve.

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30-115

Hydraulic system Testing hydraulic oil cooler performance

Hydraulic oil cooler oil pressure and oil temperature characteristics

Hydraulic oil Hydraulic oil cooler cooler oil teminlet pressure perature 0.260.30 MPa 40 C {2.63.0 kg/cm2} 0.300.34 MPa 40 C {3.03.4 kg/cm2} 0.340.38 MPa 40 C {3.43.8 kg/cm2} 0.15 MPa 40 C {1.5 kg/cm2} 0.69 MPa 40 C {7.0 kg/cm2} 0.29 MPa {3.0 kg/cm2} 100 C Engine speed Low idle (650 rpm) At rated speed (1,900 rpm) High idle (2,050 rpm) Low idle (650 rpm) High idle (2,050 rpm) High idle (2,050 rpm) Flow (reference) 380 l 560 l 713 l 380 l 700 l 713 l Remarks <Reference> Cold relief valve set pressure: 0.5 MPa {5.1 kg/cm2} Surge cut valve set pressure: 0.5 MPa {5.1 kg/cm2} Cold relief valve set pressure is too low Cold relief valve set pressure is too high
q q q

30-1 6

Abnormality

Normal

Clogging inside hydraulic oil cooler Cold relief valve set pressure is too low Steering pump flow is too low

30-116

WA1200-6

Hydraulic system Bleeding air from hydraulic circuit

Bleeding air from hydraulic circuit

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 Be sure to follow "Safety precautions to follow before starting work". 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 propeller 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 engine 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".

30-1 7

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30-117

Hydraulic system Bleeding air from hydraulic circuit

Bleeding air from brake pump circuit a When the brake oil, brake line, or brake pump has been replaced with new one, perform the following air bleeding procedure. 1. Check that the oil level of the brake tank is high level. 2. Bleed air from the wheel brake circuit referring to "Bleeding air from wheel brake circuit" section. 3. Loosen the lock nut (2) of the R3 main relief valve of the accumulator charge valve (1) and return the main relief valve (3) until only a minimal amount of pressure is applied to the 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 returned to their respective original positions.

30-1 8 4. Start the engine and show the brake oil pressure of Pm Clinic on the KOMTRAX Plus screen. 5. Let the engine run for five minutes. When the brake oil pressure is normal, return the R3 main relief valve (3) of the accumulator charge valve to its original position and tighten the lock nut (2). 6. Check the oil level of the brake oil tank again and add oil as necessary. 7. Depress the foot brake and make sure that the brake circuit operates correctly and the brake charge cut in/out pressures are normal.

30-118

WA1200-6

Hydraulic system Bleeding air from hydraulic circuit

Bleeding air from piston pump a When oil of the hydraulic tank or the piston pump has been replaced with a new one, or the piston pump pipe has been replaced, bleed air from the circuit by following the procedure given below to prevent pump seizure. 1. Preparation Add oil to the H level of the tank level gauge (1). (Type of oil: SAE 10WCD or H046-HM)

30-1 9 2. Bleeding air from piston pump 1) Loosen the air bleeder plug (1) on the upper surface of the tube on the piston pump suction side, the plugs (3) and (4) on the upper surface of the steering pump and the switch pump, and the fittings of the hose (2) 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.

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30-119

Hydraulic system Bleeding air from hydraulic circuit

Bleeding air from the oil filter of the hydraulic 30-120 tank a If the oil in the hydraulic tank, piston pump, control valve, or the hydraulic cylinder has been replaced with a new one, bleed air from the oil filter of the hydraulic tank by following the procedure given below. 1. Check that the hydraulic oil is full up to the window in the hydraulic tank sight gauge (1).

30-120 Bleeding air from work equipment circuit a When the hydraulic oil control valve or work equipment cylinder has been removed and reinstalled, bleed the system of air by following the procedure given below. 1. Add oil to the hydraulic tank until the oil level reaches the window in the 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.

3. Start the engine and set its speed to low idle. 4. With oil overflowing from plugs (1), (2), (3), and (4), indicating that the filter has been completely bled of air, tighten the plugs (1), (2), (3), and (4).

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).

30-120

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Hydraulic system Bleeding air from hydraulic circuit

5. Run the engine at low idle. 1) Slowly move the lift arm and bucket cylinder just before the stroke end. q Never let the relief valves actuate. q Raise and lower the lift arm and tilt and dump the bucket four to five times repeatedly. 2) Slowly move the lift arm and bucket cylinders up to the stroke end. q Never let the relief valves actuate. q Raise and lower the lift arm and tilt and dump the bucket four to five times repeatedly. 6. Stop the engine and loosen plugs (1) to (4). 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. 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.

8. Run the engine at 1,500 rpm and slowly move the lift arm and bucket cylinders to the stroke end. q Never let the relief valves actuate. q Raise and lower the lift arm and tilt and dump the bucket four to five times repeatedly. 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 bled. 11. When the air is completely bled, check the oil level. Add oil as necessary until the level reaches the Full mark in the sight gauge.

7. Lower the bucket to the ground and check the oil level. Then, add oil up to the window in the sight gauge (1).

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30-121

Hydraulic system Releasing remaining pressure in hydraulic circuit

Releasing remaining pressure in hydraulic circuit

k

30-12

Be sure to follow "Safety precautions to follow before starting work".

Releasing remaining pressure between each hy30-12 draulic cylinder and control valve a If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining pressure from the circuit as follows. 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 accumu30-12 lator circuit a When disconnecting the piping between the accumulator and accumulator check valve, or the piping between the accumulator and brake valve, remove the remaining pressure in the circuit 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 accumula30-12 tor circuit a If the piping between the PPC accumulator and PPC valve is to be disconnected, release the remaining pressure from the circuit as follows. a Operate the control lever two to three times to release all the remaining pressure from the circuit.

30-122

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Work equipment Checking center hinge pin lubrication

Work equipment
k k k k

Checking center hinge pin lubrication

Be sure to follow "Safety precautions to follow before starting work". Park the machine on a flat and firm ground. Lower the bucket to the ground and apply the parking brake. Chock the wheels to prevent the machine from moving.

30-123
a If fresh grease is not oozing out from bearing end surfaces (a) and (b), fill grease until fresh grease comes out.

30-123

30-123 Checking To prevent damage to the center hinge portion bearings due to insufficient lubrication by the auto-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 surfaces (a) and (b).

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Work equipment Checking center hinge pin lubrication

a When filling grease manually, use the injectors marked by asterisks (*) in the drawing below (two places).

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Work equipment Adjustment method of auto grease injector delivery

Adjustment method of auto grease injector delivery

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 against stopper Back-off counterclockwise 10 turns from above position
q

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0.13 cc (Min.) 1.30 cc (Max.)

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.

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Work equipment Setting method of auto grease timer

Setting method of auto grease timer

k

30-126
2. Adjusting interval time (blue dial) Open the bottom door at the rear of the cab. Open the lid of the timer box. Turn the blue dial illustrated on the right to adjust interval and operating times. To adjust interval time, turn the blue rotary switch (1) illustrated on the right in accordance with the table on the next page.

After adjustment, correctly close the lid on the timer box to prevent water ingress. The timer is provided to control greasing intervals of the auto grease system. The timer is installed in box (1) behind the operator seat. Greasing intervals can be changed as needed in 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)

q q q

Example: Set to 11.25 minute

11.25 min. pause 11.25 min. pause 11.25 min. pause Running

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 operating 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.

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Work equipment Setting method of auto grease timer

Position of switch Greasing interval (min.) Position of switch Greasing interval (min.)
q

1 3.75 A 37.5

2 7.5 B 41.25

3 11.25 C 45

4 15 D 48.75

5 18.75 E 52.5

6 22.5 F 56.25

7 28.25

8 30

9 33.75

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 Greasing interval (sec.) Position of switch Greasing interval (sec.)

1 7.5 A 75

2 15 B 82.5

3 22.5 C 90

4 30 D 97.5

5 37.5 E 105

6 45 F 112.5

7 58.5

8 60

9 67.5

1) Set the red dial to "2". (under normal operating 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.

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Electrical system Testing and adjusting bucket proximity switch

Electrical system
k

Testing and adjusting bucket proximity switch

Be sure to follow "Safety precautions to follow before starting work".

30-128

30-128

30-128 Checking 1. Start the engine and operate the bucket to activate proximity switch (1). Stop the engine and measure clearance a between the proximity switch and angle (2). a Standard clearance: a = 3 to 5 mm

4. Since angle (2) moves laterally in relation to the sensing surface of the switch, adjustment should be made so that clearance a is 3 to 5 mm along the entire length of the angle that passes the front of the switch.

2. Run the engine at around 1,500 rpm, let the proximity switch activate, and lower the bucket to the ground. Check if the bucket angle is 0 to 1 deg. downward. 30-128 Adjusting 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}

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 1,500 rpm, positioner activated, and the bucket lowered to the ground. a The nominal position of the bracket is c=139 mm on a standard set.

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.

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Electrical system Adjusting lift arm potentiometer

Adjusting lift arm potentiometer

k

30-129

Be sure to follow "Safety precautions to follow before starting work". 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
Conditions Maximum lift arm angle Minimum lift arm angle Standard value 4.33 0.33 V 0.66 0.33 V

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Electrical system Adjusting lift arm levelness detecting switch

Adjusting lift arm levelness detecting switch

k

30-130

Be sure to follow "Safety precautions to follow before starting work". a Lateral adjustment 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 position. a Standard clearance: d=3 to 5 mm 3 Nut: 14.7 to 19.6 Nm {1.5 to 2.0 kgm}

6. Adjust at the oblong hole in bracket (4) so that cover (2) overlaps with half of the sensitive surface of proximity switch (1). a See Fig. Y

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).

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Electrical system Initial setting procedure for remote boom positioner (origin input method)

Initial setting procedure for remote boom positioner (origin input method)
a Perform this setting to accomplish "Adjusting lift arm potentiometer". 1. Select "Service Menu"o"Adjustment Menu"o"Boom Angle Sensor Adjustment" on the multi meter display screen and depress the "F6" switch.

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3. "Setting" is displayed, and when the automatic correction calculation is finished, 1) "Setting Completed" is displayed. Press switch "F1" to finish the setting. 2) If "Wrong Value" is displayed, perform the setting again from step 2.

2. Follow the screen (Raise boom to upper limit (stroke end) and press the Set button), and press "F6".

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Electrical system Checking proximity switch operation pilot lamp

Checking proximity switch operation pilot lamp

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 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
q

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Electrical system Adjusting AJSS lever angle sensor and frame angle sensor

Adjusting AJSS lever angle sensor and frame angle sensor

k

30-13

Be sure to follow "Safety precautions to follow before starting work".

30-13 Adjusting 1. Move the frame lock bar to the "LOCK" position and set the machine in the straight travel position.

3. In this condition, measure the voltage at frame angle potentiometer (2) and lever angle potentiometer (4). a Voltage when potentiometer is in neutral position: 2.5 0.3 V 4. If the voltage is not 2.5 0.3 V, loosen mounting 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 dimension. a L Standard length: 342 mm

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Electrical system Testing and adjusting potentiometer mounting position

Testing and adjusting potentiometer mounting position

k

30-134

Be sure to follow "Safety precautions to follow before starting work". a The potentiometers can be checked for correct position on the multi monitor screen (See "Adjusting steering follow-up linkage"). Preparation work a Before checking, ensure that all the related connectors are properly inserted. a Keep the joystick steering lever in the NEUTRAL position unless it is used. a Be sure to connect any disconnected connectors to the original configuration before going on to the next step. a Connect a T-adapter and turn the starting switch to "ON".

2. Checking the frame angle potentiometer for correct position 1) With the engine started and set at low idle, move the steering lever fully to the right or left. 2) With the lever at the end of stroke, check the voltage between (3) and (10) of connector L05 (female) on the work equipment controller. Alternatively, with the lever at the end of stroke, check the voltage between (1) and (3) of connector L30 (male) on the potentiometer. a Potentiometer voltage standard value
Item Frame angle, right Frame angle, left Standard value 0.5 to 1.5 V 3.5 to 4.5 V

30-134 Testing 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 Steering lever angle, right Steering lever angle, left Standard value 3.5 to 4.5 V 0.5 to 1.5 V

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Electrical system Testing and adjusting potentiometer mounting position

Related electrical circuits

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Electrical system Testing and adjusting potentiometer mounting position

30-136 Adjusting a If the potentiometer position voltage is out of the standard value, adjust following the steps below. 1. Adjusting the frame angle potentiometer 1) Check and ensure that length "L" of steering follow-up linkage (1) agrees with the standard 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 potentiometer mounting screw (3) and recheck the potentiometer voltage.

2. Adjusting the steering lever angle potentiometer 1) Loosen mounting screw (5) for steering lever angle potentiometer (4).

2) With the steering lever moved right or left to the end of stroke, check the voltage of potentiometer (4). 3) Turn potentiometer (4) until the voltage reading comes to agree with the standard value. 4) After completing adjustment, tighten potentiometer mounting screw (5) and recheck the potentiometer voltage.

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Electrical system Procedure for testing diodes

Procedure for testing diodes

Test the single diode and the wiring harness with built-in diode according to the following procedure. 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.
q

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30-137

Electrical system Basic precautions for KOMTRAX Plus controller

Basic precautions for KOMTRAX Plus controller

1. Machine handling, safety, and maintenance For safety precautions, operation, maintenance of the machine, see the "Operation and Maintenance Manual" of the machine. 2. Handling the monitoring system Observe the following precautions for handling of the monitoring system. 1) Disassemble, repair, or modify the machine and system according to the manual. 2) Do not touch the system while the machine is operating. 3) Do not allow harnesses, connectors, or sensors to become caught; do not damage harnesses, connectors, or sensors by pulling them by force. Short circuits or disconnected wires may cause failure or fire on the system or the machine itself. 4) Take care to stick water, dust, or oil to the system. 3. Continuous power supply (battery direct power supply) of the KOMTRAX Plus 1) Meaning and necessity of the continuous power supply KOMTRAX Plus has a function of determining and keeping a record of machine statuses for the period from "starting switch ON" to "starting switch OFF", thus requiring a different power supply from that for many other electronic devices and components.

30-138

To achieve the above function, a power supply (continuous power supply) which is directly wired from the battery and to which power is constantly supplied from the battery, in addition to the power supply (switch power supply) that is shut down when the "starting switch is turned OFF" or "engine is stopped". The presence of the switched power supply and the continuous power supply identifies a period during which data must be identified, thereby allowing the data for that particular period to be stored in the internal memory. That is, KOMTRAX Plus uses the continuous power supply to store the data accumulated during the period from "starting switch ON" to "starting switch OFF" in the memory before letting the KOMTRAX Plus controller shut down the continuous power supply. 2) Precautions for shutting down the continuous power supply Shut down the continuous power supply after a lapse of three minutes (period of time required to turn OFF the KOMTRAX Plus system, or the period of time required for data to be stored in memory) after "starting switch OFF". The accumulated data may be destroyed if the system OFF time is shorter than three minutes. The system OFF time varies depending on 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.

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Electrical system Basic precautions for KOMTRAX Plus controller

2] Mounting a battery isolator or other power shutoff device 1] Basic connections The basic applicable rule to go by is to mount an engine stop switch that will not shut down the continuous power supply. 2] If shutdown of all power is unavoidable because of user's safety regulations or other reason q Mount the battery isolator such that the continuous power supply is shut 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 continuous power supply. q Accumulated data may be destroyed if the retention time is shorter than above.

4. Precautions for turning "ON" the KOMTRAX Plus power supply q The KOMTRAX Plus controller performs an initial check sequence (LED flashing off and on) for the first several tens of seconds after the power is turned "ON". Do not perform any of the following steps during this period. q Operating the manual snap shot switch q Downloading by PC (Perform these steps after making sure that the LED shows a total number in sequence.)

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Electrical system Basic precautions for KOMTRAX Plus controller

5. Precautions for replacing KOMTRAX Plus and transmission controller 1) Before starting the replacement procedure 1] Downloading the KOMTRAX Plus data Download the accumulated data before replacing the KOMTRAX Plus controller with a new one. Be careful that data accumulated up to the point of replacement will be lost by the replacement. Next, send this accumulated data to the WebCARE. Download the data according to the instructions given in the separate "Analysis tool instruction manual".

Replace the KOMTRAX Plus controller with a new one with care not to subject the controller main body and harnesses to excessive force or impact. Then, perform the "initial setting" procedure by following the instructions given in the "analysis tool instruction manual". 6. Handling the communication (ORBCOMM) controller 1) The ORBCOMM controller needs an application (for opening the communication line) before it can be used. k If the controller is turned ON before the application is properly processed, the communication system fails due to unauthorized data transmission. Ask the operating administrator or your Komatsu distributor for any query. 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

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Electrical system Basic precautions for KOMTRAX Plus controller

7. Trend data items Table 1: Trend analysis data

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

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Electrical system Basic precautions for KOMTRAX Plus controller

No. 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

Item Atmos. Pres.Ave AMBIENT TMP.MAX AMBIENT TMP.AVE AMBIENT TMP.MIN 0 - 30 ton - 31 ton - 32 ton - 33 ton - 34 ton - 35 ton - 36 ton - 37 ton - 38 ton - 39 ton - 40 ton - 42 ton - 44 ton - 46 ton - 48 ton - 50 ton 50 - ton

Content Ambient pressure (mean) Outside air temperature (max) Outside air temperature (average) Outside air temperature (min) Loadmeter value : 30 tons or less : - 31 tons : - 32 tons : - 33 tons : - 34 tons : - 35 tons : - 36 tons : - 37 tons : - 38 tons : - 39 tons : - 40 tons : - 42 tons : - 44 tons : - 46 tons : - 481 tons : - 50 tons : 50 tons or more

Unit hPa degC degC degC times times times times times times times times times times times times times times times times times

Remarks

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Electrical system Basic precautions for KOMTRAX Plus controller

Table 2.1: Transmission trend data

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Item Exh.Temp LF 700Exh.Temp LF 750Exh.Temp LF 800Exh.Temp LR 700Exh.Temp LR 750Exh.Temp LR 800Exh.Temp RF 700Exh.Temp RF 750Exh.Temp RF 800Exh.Temp RR 700Exh.Temp RR 750Exh.Temp RR 800F Fill Time R Fill Time 1st Fill Time 2nd Fill Time 3rd Fill Time F Trg. Time R Trg. Time 1st Trg. Time 2nd Trg. Time 3rd Trg. Time TC Oil T.120TC Oil T.130TC Oil T.140Brake T.120Brake T.130Brake T.140Content E/G use time by exhaust temp : from 700 degC to 750 degC (L-1,2,3,4) E/G use time by exhaust temp : from 750 degC to 800 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 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) E/G use time by exhaust temp : 800 degC or more (L-5,6,7,8) E/G use time by exhaust temp : from 700 degC to 750 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) E/G use time by exhaust temp : 800 degC or more (R-1,2,3,4) E/G use time by exhaust temp : from 700 degC to 750 degC (R-5,6,7,8) E/G use time by exhaust temp : from 750 degC to 800 degC (R-5,6,7,8) E/G use time by exhaust temp : 800 degC or more (R-5,6,7,8) T/M F cluch fill up time (average) T/M R cluch fill up time (average) T/M 1st cluch fill up time (average) T/M 2nd cluch fill up time (average) T/M 3rd cluch fill up time (average) T/M F cluch trigger time (average) T/M R cluch trigger time (average) T/M 1st cluch trigger time (average) T/M 2nd cluch trigger time (average) T/M 3rd cluch trigger time (average) T/C use time by oil temp : from 120 degC to 130 degC T/C use time by oil temp : from 130 degC to 140 deg C T/C use time by oil temp : 140 degC or more Brake use time by oil temp : from 120 degC to 130 degC Brake use time by oil temp : from 130 degC to 140 deg C Brake use time by oil temp : 140 degC or more Unit sec sec sec sec sec sec sec sec sec sec sec sec msec msec msec msec msec msec msec msec msec msec sec sec sec sec sec sec Remarks

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Electrical system Basic precautions for KOMTRAX Plus controller

Table 2.2: Vehicle used trend data

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Item Tire Srip counttime TM Cutoff SW time VHCL SPD SW time MCN SPDSET - 4 km MCN SPDSET - 6 km MCN SPDSET - 8 km MCN SPDSET - 10 km MCN SPDSET 10 km DRV PWR - 30 ton DRV PWR - 50 ton DRV PWR - 70 ton DRV PWR - 110 ton DRV PWR 110 ton THR - 20 % DC on THR - 40 % DC on THR - 60 % DC on THR - 80 % DC on THR 80 % -DC on THR - 20 % DC off THR - 40 % DC off THR - 60 % DC off THR - 80 % DC off THR 80 % -DC off Manualshift time Semi-auto Loose Semi-auto Rock Active PWRUP off Content Frequency of tire slip T/M cut off SW ON used time Vehicle speed control SW ON used time Vehicle speed set time by 4 km/h or less Vehicle speed set time by from 4 km/h to 6 km/h Vehicle speed set time by from 6 km/h to 8 km/h Vehicle speed set time by from 8 km/h to 10 km/h Vehicle speed set time by 10 km/h or more Driving performance set time by 30 ton or less Driving performance set time by from 30 ton to 50 ton Driving performance set time by from 50 ton to 70 ton Driving performance set time by from 70 ton to 110 ton Driving performance set time by 110 ton or more Throttle lock sw set time by 20 % or less Throttle lock sw set time by from 20 % to 40 % Throttle lock sw set time by from 40 % to 60 % Throttle lock sw set time by from 60 % to 80 % Throttle lock sw set time by 80 % or more Throttle lock sw set time by 20 % or less Throttle lock sw set time by from 20 % to 40 % Throttle lock sw set time by from 40 % to 60 % Throttle lock sw set time by from 60 % to 80 % Throttle lock sw set time by 80 % or more Manual shift used time Semi auto SW set time (Loose) Semi auto SW set time (Rock) Active Power cancel SW used time Unit time sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec sec Loose mode Rock mode Auto decel on Auto decel on Auto decel on Auto decel on Auto decel on Auto decel off Auto decel off Auto decel off Auto decel off Remarks

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Table 3.1:Auto snap shot monitor items (trigger items)

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Coolant temperature is high Left bank front intake temperature is extremely high Right bank front intake temperature is extremely high Left bank rear intake temperature is extremely high Right bank rear intake temperature is extremely high Engine oil temperature is extremely high Coolant pressure sensor signal is extremely low Eng Overspeed Fuel temperature is high Engine oil pressure is extremely low Engine oil temperature is high Crankcase internal pressure is extremely high Left bank front intake temperature rises abruptly Left bank No. 1 cylinder exhaust temperature is high Left bank No. 2 cylinder exhaust temperature is high Left bank No. 3 cylinder exhaust temperature is high Left bank No. 4 cylinder exhaust temperature is high Left bank No. 5 cylinder exhaust temperature is high Left bank No. 6 cylinder exhaust temperature is high Left bank No. 7 cylinder exhaust temperature is high Left bank No. 8 cylinder exhaust temperature is high Right bank No. 1 cylinder exhaust temperature is high Right bank No. 2 cylinder exhaust temperature is high Right bank No. 3 cylinder exhaust temperature is high Right bank No. 4 cylinder exhaust temperature is high Right bank No. 5 cylinder exhaust temperature is high Right bank No. 6 cylinder exhaust temperature is high Right bank No. 7 cylinder exhaust temperature is high Right bank No. 8 cylinder exhaust temperature is high Right bank front intake temperature rises abruptly Left bank rear intake temperature rises abruptly Right bank rear intake temperature rises abruptly Parking brake dragging detected T/C oil temperature overheat (120 C) Hydraulic Oil Overheat Brake Oil Overheat Front brake oil pressure drops Rear brake oil pressure drops T/M overrun alarm Manual snapshot Item FAULT CODE CA146 CA155 CA158 CA162 CA165 CA214 CA228 CA234 CA261 CA415 CA421 CA556 CA783 CB2121 CB2122 CB2123 CB2124 CB2125 CB2126 CB2127 CB2128 CB2131 CB2132 CB2133 CB2134 CB2135 CB2136 CB2137 CB2138 CA2157 CA2158 CA2159 989S00 b@CENS B@HANS B@C6NS 2G42ZG 2G43ZG 1540N1 MFA0

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Electrical system Basic precautions for KOMTRAX Plus controller

Table 3.2:Manual snap shot monitor items

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 TIME ENG.SPEED TM ENG.SPEED FUEL INJECT. RAIL PRE. BLOW-BY PRE. BOOST PRE. ENG. OIL TEMP. ENG. OIL PRE. COOLANT TEMP. Exh. TEMP. LF Exh. TEMP. LR Exh. TEMP. RF Exh. TEMP. RR Accelerator Pos. PPC OIL PRES LOADER PUMP PRES HYD. OIL TEMP Lever V. Boom1 Lever V. Bkt1 Boom Bottom P. Boom Head P. Boom Angle ST PUMP PRES AJSS L. V. Boom1 Flame Angle SHIFT INDICATOR T/M Out Speed VEHICLE SPEED T/C OIL TEMP. M/C Out Speed M/C SLIP RATE M/C Press F Brake Press R Brake Press Brake Oil Temp L BRAKE PRESS Right Brake SW AMB. AIR TEMP. ECO. MODE Item Engine speed Engine speed (TM calculationvalue) Fuel injection rate Fuel rail pressure Blow-by pressure Boost pressure Engine oil temperature Engine oil pressure Engine coolant temperature Exhaust temperature (L-1,2,3,4 max) Exhaust temperature (L-5,6,7,8 max) Exhaust temperature (R-1,2,3,4 max) Exhaust temperature (R-5,6,7,8 max) Accelerator position. PPC oil pressure Loader pump pressure Hydraulic oil temperature Boom lever potentiometer voltage Bucket lever potentiometer voltage Boom bottom Pressure. Boom haed Pressure. Boom angle S/T pump presssure AJSS lever potentiometer voltage Frame angle Present Shift position T/M outlet shaft speed Travel speed T/C oil temperature Mod/C output shaft speed Mod/C slip ratio Mod/C oil pressure F brake charge oil pressure R brake charge oil pressure Brake oil temperature Left brake oilpressure Right brake SW ON/OFF Ambient air temperature ECO. Mode ON/OFF Content Time from snapshot generation Unit sec rpm rpm mm3/st MPa kPa kPa degC kPa degC degC degC degC degC % MPa MPa degC mV mV MPa MPa deg MPa mV deg rpm km/h degC rpm % MPa MPa MPa degC MPa degC 1 o F1, 2 o F2, 3 o F3 -1 o R1, -2 o R2, -3 o R3 Remarks

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Electrical system Inspection and maintenance of KOMTRAX Plus controller

Inspection and maintenance of KOMTRAX Plus controller

1. Time of inspection: When performing inspection 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 remedies 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 antenna mounting. q Check for damage, looseness, or play in the antenna body. q If any failure is found, replace the antenna. 3) Maintenance when required 1] Check each sensor if downloaded value is abnormal. 3. Remedy If any failures are found, repair, replace, or reinstall (retighten).

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Initial setting procedure for KOMTRAX Plus controller

a Initial setting equipment for KOMTRAX Plus controller
Symbol ZB 2 Part No. 799-608-3211 1 799-608-3220 Commercially available Part name CD-ROM Wiring harness Laptop type personal computer (PC): Windows98/2000/Me/XP

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a Before starting full operation after completion of local assembly or before resuming operation after storage for a long period, initialize the KOMTRAX Plus controller according to the following procedure. a Machine data collected by the KOMTRAX Plus controller are stored and managed in the WebCARE 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 initialization. a For the installation procedure of the KOMTRAX Plus initial setting program to a personal computer, refer to the operation and maintenance manual being bundled with the service kit ZB1. a Since the service menu of the monitor panel will be used in the following procedure, read "Special functions of monitor panel" and understand the operating procedure in advance. a The initial setting procedure covers both the ORBCOM specification and the ORBCOM-less specification. When using the ORBCOM-less specification unit, follow the procedure while bypassing 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.

1. Check of machine information, engine information, transmission controller information and controller information a This step is a work performed on the whole machine. Check and record the machine information, engine information, KOMTRAX Plus controller information, and ORBCOMM terminal information.
No. 1 2 3 4 5 6 7 Information to be checked Machine model Machine serial No. Current service meter reading Engine serial No. Transmission serial No. KOMTRAX Plus controller serial No. ORBCOMM terminal serial No. [Only for machines equipped with ORBCOM]

2. Connection of personal computer a This step is a work performed in the operator's cab. 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. a Connect it to RS232C terminal on the PC.

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3. Start-up of KOMTRAX Plus initial setting tool a This step is a work performed in the operator's cab (on the PC). 1) Turn on the PC and start the OS. 2) Click the icon of [KOMTRAX Plus Initial Setting Tool] on the PC to start the KOMTRAX Plus initial setting tool. Important a The setting screen varies with the version No. of the KOMTRAX Plus setting tool. a When using a tool before Ver. 3.5.2.1 (CD-ROM), set the KOMTRAX Plus in 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 WebCARE 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.

4. Initial setting of VHMS controller (Ver. 3.5.2.1 or older version) a This work is done inside the cab (from PC). a It is prohibited in the initial setting to modify the data of service meter [SMR]. [Machine Information] 1) The [Machine information] tab is displayed first in the [Data clear and Set up] menu, and the screen data are read automatically. 2) The default initial screen appears. (Initial screen set at the delivery time) 3) Check all the data.

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4) If the information in the [Date/Time] box is not correct, change it according to the following procedure: 1] Press the [Edit] button (1) in the [Date/Time] box to display the correction screen. 2] The pull-down menu appears in the [TimeZone] box. Press the [r] button to scroll the screen and select the correct information.

5) If the information in the [Machine information] box is not correct, change it according to the following procedure: 1] Press the [Edit] button (2) in the [Machine information] box to display the correction screen. 2] When changing the variation code, press the [r] button in the pull-down menu to select the code to be changed. 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 corresponding box. q Engine Serial No. 1: Engine serial No. q Engine Serial No. 2: Transmission serial 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.

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6) After checking and changing all the data of [Machine information], press [Apply] button (3) to settle the setting. a If [Apply] button (3) is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.

4-1.Setting of PLM data 1) Open the [PLM] tab and go to the setting screen. In the default mode (which was set when delivered), collection of the data is started at 0:00 AM to collect the data of 1 day. 2) Press the [Edit] button (5) to go to the screen for setting the collection start time and collection 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).

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4-2.Setting of ORBCOMM communication [For ORBCOMM specification only] q Open the [Communication Setting] tab. q Check all the data.

2) To change setting of [SHORT TREND ANALYSIS], follow the procedures below. 1] Select [SHORT TREND ANALYSIS] on 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 Setting] block to display the setting screen. 2] Change the setting and then press the [OK] button. a When setting up, select [Occurrence] in the [Timing] box, and set the function to [ON].

3] The confirmation screen appears again. If the setting is correct, press the [Y] button to finish setting. 4] After checking and changing all the data, press the [Exit] button at the right bottom of the screen to turn the software OFF.

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3) To change the setting of [Satellite Setting], follow the procedure below. 1] Press the [Edit] button (6) in the [Satellite Setting] block to display the setting 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.

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3] Press the [Apply] button. q Only the changed data are displayed. Check them and press [OK] button (9).

5. Initial setting of KOMTRAX Plus controller (Ver. 3.5.2.1 or later version) a This work is done inside the cab (from PC). 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 and turn the starting switch OFF.

2) Select [Set up & All clear] and press the "Next" button.

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3) Check the machine information. If it does not need to be corrected, press the "Next" button.

4) Select the time zone. 5) Input the local time. 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 advanced 1 hour automatically, thus the time must be corrected again.

a If the KOMTRAX Plus was installed additionally, 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 1 Area N. America (*1) C.S. Americas Faroe Islands Europe (*2) Middle East Asia (*3) Africa (*4) Oceania CIS Japan Remarks *1: Except U.S. Territories in Micronesia and Midway Island *2: Except Faroe Islands *3: Except Japan *4: `Globalgram mode is required

120

130

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8) Finally, check the new setting displayed on the screen. To confirm, press the "Apply" button.

6. Checking saving operation of KOMTRAX Plus controller 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.

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7. Performing Quick Pm Clinic 1) Start the engine and run it at low idle. 2) Set the lock lever in the FREE position. 3) Set the machine management (multi) monitor to display the service menu selection screen. a See "Functions and operation of machine management (multi) monitor". 4) Select [Snapshot Trigger] and press "Selection" (F6) switch.

6) Operate the switches and levers at each execution time according to the " Operating procedure for quick Pm Clinic" shown in the following table. a The execution times are displayed on the machine maintenance (multi) monitor. k The work equipment is operated and the machine travels actually during the 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. a While the following screen is displayed, press [F5] (Yes), and the check message is displayed. a Before starting the snap shot operation, fully understand the operating procedure for the snap shot. q See Structure and Operation, "Multi Monitor".

Important The data of the Quick Pm Clinic is recorded only once. If the Quick Pm Clinic is executed again, the current data are overwritten. Executing the Quick Pm Clinic overwrites data. Accordingly, be sure to save the data in the personal computer after executing the Quick Pm Clinic, referring to "8. Downloading 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.

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8. Quick Pm Clinic implementation procedure

1. 800 rpm Operat- Engine ing conditions and sequence T/M Shift switch Operating conditions 1-1 (Min0.0 utes) (Min-5.5 utes) Engine speed 1/4 2. Eng Low idle 3. Engine Full Bucket Tilt Back Relief N 3.5 -2.0 1/4 4.0 -1.5 4. 5. Engine Full Eng High Steering Idle Relief 6. 7. Engine Full Eng Low T/C Stall idle 8. Eng High Idle 9. 10. Engine Full Eng Low Full Stall idle

N 0.5 -5.0 1/4

N 4.5 -1.0 1/4

N 5.0 -0.5 1/4

F3 5.5 0.0

N 6.0 0.5

N 6.5 1.0 1/4

F3 7.0 1.5 a

N 7.5 2.0

1-2

Engine oil pressure Blowby Pressure Boost pressure

1/4

1/4

1-3

2/4

1-4

2/4

1-5

Ambient Temper- 2/4 ature T/C Inlet Pressure T/C Outlet Pressure T/M Main Relief Pressure T/M Lubricating Oil Pressure T/M Mod Oil Pressure Steering circuit relief pressure Brake Charge Cut-in (*1) Brake Charge Cut-out (*1) Work equipment relief pressure PPC Oil Pressure 4/4 4/4 3/4

2-1

2-2

3/4

3-1

3/4

3-2

3/4

3-3

3/4

4/1

5-3

4/4

5-3

4/4

6-1

6-2

4/4

(*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.

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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 For the operation procedures, refer to the operation manual for the KOMTRAX Plus Technical Analysis Tool. a Make sure that downloading has completed before proceeding to the next step.

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10. Check of downloaded data a This step is a work performed in the operator's cab (on the PC). 1) Check the setting data by using [View] function. a Display the graph using the "View" function of the analysis tool. Measure the data of each item. (Example: Engine speed)

a For the operation procedures, refer to the operation manual for the KOMTRAX Plus Technical Analysis Tool. 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 recorded. 2) After checking the setting data, terminate [KOMTRAX Plus Technical Analysis Tool].

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11. Disconnecting the PC 1) Make sure that starting switch is in the OFF position. k When connecting and disconnecting the PC, be sure to turn the starting switch to the OFF position. 2) Shutdown the OS of PC ZB2 and then turn off the PC power. 3) Disconnect the harness ZB1 from the download connector DL1.

12. Report to Komatsu After completing steps 1 to 11 successfully, send the "KOMTRAX Plus/WebCARE setting notification form" to KOMTRAX Plus/WebCARE Support Center of Komatsu, Tokyo. a Since Komatsu has to set the receiving side of the satellite communication, be sure to inform Komatsu of the completion of the setting. 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

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[For storage] KOMTRAX Plus initial setting work check sheet

Setting step Model name Serial No. Check of nameplates of chassis and 1 components Engine serial No.

Date of setting: DB/branch name: Filled by: Check item

Year Month Day

Results

Transmission controller serial No. KOMTRAX Plus controller S/No. 2 3 4 Connection of PC with KOMTRAX Plus controller Checking operation of KOMTRAX Plus controller Start-up of KOMTRAX Plus initial setting tool Initial setting procedure for KOMTRAX Plus controller 5 (Setting of machine information) In this step, basic machine body information are set on KOMTRAX Plus controller) 6 Saving of set items 7 Check of KOMTRAX Plus function 8 Performing Quick Pm Clinic 9 Saving operation of KOMTRAX Plus 10 Downloading Is the connection secure? Is it operating normally? (Displays decimal counting in ascending-order succeeding to rotation) Is "Data Clear and Set up" selected for the setting tool mode? Is model name identical with machine body? Is machine body serial No. correctly entered? Is engine serial No. correctly entered? Is today's date entered? Is current time entered? Is SMR correctly entered? Is LED (7-segment) turned off? Is LED operation normal? Is service mode "SNAPSHOT" turned on and is the switch pressed? Is LED (7-segment) turned off? Is LED operation normal? Are all files downloaded? The time downloaded (Reference wrist watch) 11 Check of download data [Check of data] Is [MFA0] error present in Fault History? Are SMR and time in Fault History consistent with settings? Is any data missing in Snap Shot? 12 Saving operation of KOMTRAX Plus Is LED (7-segment) turned off? yes yes yes yes no no no no yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes no no no no no no no no no no no no no no no

CatHour egor y

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[For storage] ORBCOMM Station Establishment Check Sheet

Setting step Machine model Serial No. 1 Check of nameplates of chassis and components Engine serial No.

Date of setting: DB/branch name: Filled by: Check item

Year Month Day

Results

Transmission serial No. KOMTRAX Plus controller S/No. ORBCOMM controller serial No.

Connection of PC with KOMTRAX Plus controller Checking operation of KOMTRAX Plus controller Start-up KOMTRAX Plus initial setting tool Initial setting procedure for KOMTRAX Plus controller 1. Setting for communication (Machine information and PLM have been set)

Is the connection secure? Is it operating normally? (Displays counting in ascending-order succeeding to rotation) Is "Set up" selected for the setting tool mode? Enter set value of S.Fault History. Execution of communication Number of communication (Default: 8) Enter set value of S.Trend Analysis. Execution of communication

yes

no

3 4

yes yes

no no

On

Off hrs

On

Off hrs

Interval (Default: 20H) Enter set value of S. Payload data. Execution of communication Time to start collection Collection interval (Number of days) 2. Setting for start of communication Is GCC code set? (130 for Japan) Is LED (7-segment) turned off after saving operation? yes yes yes On

Off

day no no no

6 Saving of set items 7

How is decimal point display in KOMTRAX Plus monitor Check of operation of ORBCOMM con(7-segment)? troller (Off, On, long/short blinking)

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Electrical system Precautions for replacing KOMTRAX Plus controller

Precautions for replacing KOMTRAX Plus controller

a Setting equipment for replacement KOMTRAX Plus controller
Symbol 1 ZB 2 Part No. 799-608-3211 CD-ROM 799-608-3220 Wiring harness Laptop type personal computer Commercially (PC): available (Windows98/2000/Me/XP) Part name

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of

a When the KOMTRAX Plus controller needs to be replaced, set it before removing it and set the installed new KOMTRAX Plus controller according to the following procedure. a Machine data collected by the KOMTRAX Plus controller are stored and managed in the WebCARE 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 sheet". a Information such as models shown in the figures may not be identical with actual ones. [Work before replacement of KOMTRAX Plus controller] 1. Download of the remaining data a This step is a work performed in the operator'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 Initialization procedures for KOMTRAX Plus controller, "9. Downloading of set data".

2. Connection of PC a This step is a work performed in the operator's cab. 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. a Connect it to RS232C terminal on the PC.

3. Check, saving, and writing of information set in

KOMTRAX Plus controller (Ver. 3.5.2.1 or later)

a This step is a work performed in the operator'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.

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Electrical system Precautions for replacing KOMTRAX Plus controller

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 replacement. 4) Select [Save] from [File] of the menu.

the

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 setting procedure. 8) Turns the PC power off. 9) Proceed to replacement of VHMS controllers.

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3-2. Loading the setting information to the replacing VHMS controller 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.

4) Currently saved information displayed. Press [OK] button.

will

be

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.

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8) Press [Apply] button to display contents of the setting. Check the setting again and, if it is acceptable, press [OK] button.

9) The confirmation screen will ask whether or not the data before the above setup is to be 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.

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4. Check, saving, and writing of information set in

KOMTRAX Plus controller (Ver. 3.5.2.1 or later)

a This step is a work performed in the operator'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.

4) Check all the information before replacing the controller and press the "Save" 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 Computer" in "Initialization procedure for KOMTRAX Plus controller". 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 KOMTRAX Plus controller". 2) Select [When KOMTRAX Plus needs to be replaced] and press the "Next" button.

3) Select [Save Current Setting before replacement of KOMTRAX Plus controller] and press the "Next" button.

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Electrical system Precautions for replacing KOMTRAX Plus controller

3) Select [Use Previous setting after replacement of KOMTRAX Plus controller] and press the "Next" button.

6) The system asks you if you will save the previous data. Press the "NO" button. a Usually, you do not need to save the previous 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.

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[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 replacement, send the check sheet to KOMTRAX Plus/WebCARE Support Center of Komatsu, Tokyo. a Send the data downloaded before and after replacing 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

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Electrical system Measurement procedure by downloading data in KOMTRAX Plus controller

Measurement procedure by downloading data in KOMTRAX Plus controller

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. a Connect it to RS232C terminal on the PC.

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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 start the engine. 3) Turn the steering lock switch to the OFF position. 4) Set the lock lever to the FREE position. 3. Selection of multi monitor display 1) Set the multi monitor to display the service menu selection screen. a See Structure and Operation, "Multi Monitor".) 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.

2) Operate the switches and levers at each execution time according to the " Operating procedure for quick Pm Clinic" shown in the following table. a The execution times are displayed on the multi monitor. k The work equipment is operated and the machine travels actually during the quick Pm Clinic, so ensure the safety around the machine during the work.

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5. Measurement procedure by downloading data in KOMTRAX Plus controller

1. 800 rpm Operat- Engine ing conditions and sequence T/M Shift switch Operating conditions 1-1 (Min0.0 utes) (Min-5.5 utes) Engine speed 1/4 2. Eng Low idle 3. Engine Full Bucket Tilt Back Relief N 3.5 -2.0 1/4 4.0 -1.5 4. 5. Engine Full Eng High Steering Idle Relief 6. 7. Engine Full Eng Low T/C Stall idle 8. Eng High Idle 9. 10. Engine Full Eng Low Full Stall idle

N 0.5 -5.0 1/4

N 4.5 -1.0 1/4

N 5.0 -0.5 1/4

F3 5.5 0.0

N 6.0 0.5

N 6.5 1.0 1/4

F3 7.0 1.5 a

N 7.5 2.0

1-2

Engine oil pressure Blowby Pressure Boost pressure

1/4

1/4

1-3

2/4

1-4

2/4

1-5

Ambient Temper- 2/4 ature T/C Inlet Pressure T/C Outlet Pressure T/M Main Relief Pressure T/M Lubricating Oil Pressure T/M Mod Oil Pressure Steering circuit relief pressure Brake Charge Cut-in (*1) Brake Charge Cut-out (*1) Work equipment relief pressure PPC Oil Pressure 4/4 4/4 3/4

2-1

2-2

3/4

3-1

3/4

3-2

3/4

3-3

3/4

4/1

5-3

4/4

5-3

4/4

6-1

6-2

4/4

(*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.

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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]. a For the operation procedures, refer to the operation manual for the KOMTRAX Plus Technical Analysis Tool. 3) Check the setting data by using [View] function. a Display the graph using the "View" function of the analysis tool. Measure the data of each item. (Example: Engine speed)

a For the operation procedures, refer to the operation manual for the KOMTRAX Plus Technical Analysis Tool. 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 recorded.

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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.

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Measurement procedure by multi monitor

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 position. 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. 2) Check the indication of the engine coolant temperature gauge and the torque converter oil temperature gauge.

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4. Measuring with "PM CLINIC MENU (1/4)" 1) Display "PM CLINIC MENU (1/4)". 2) Measure the engine speed, engine oil pressure, 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".

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5. Measuring with "PM CLINIC MENU (2/4)" 1) Display "PM CLINIC MENU (2/4)". 2) Measure the engine speed, blow-by pressure, boost pressure, exhaust gas temperature, ambient temperature, and fuel rail pressure. a For the measurement conditions, see the check sheet.

7. Measuring with "PM CLINIC MENU (4/4)" 1) Display "PM CLINIC MENU (4/4)". 2) Measure the hydraulic oil temperature, PPC oil pressure, hydraulic oil pressure, steering pump oil pressure, front brake oil pressure, and rear brake oil pressure. a For the measurement conditions, see the check sheet.

6. Measuring with "PM CLINIC MENU (3/4)" 1) Display "PM CLINIC MENU (3/4)". 2) Measure the torque converter oil temperature,torque converter inlet pressure,torque converter outlet pressure,transmission main pressure, transmission lubricating oil pressure, and transmission modulation pressure. a For the measurement conditions, see the check sheet.

8. Measuring work equipment speed and hydraulic drift Using a stopwatch, scale, etc., measure the work equipment speed and hydraulic drift.

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Special functions of multi monitor

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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 inspection, maintenance, and troubleshooting.
Operator mode 1 2 3 4 5 6 7 8 9 Clock/engine speed display function Monitor contrast/brightness adjusting function Productivity/production history display function Date/time of day adjusting function Language selection function Maintenance monitor function Failure list display function Load meter function Caution/warning display function io 1 2 3 4 5 6 7 8 9 10 Service mode Real-time monitoring function Pm Clinic function Abnormality record display function Manual snap shot function Adjustment Menu Option setting Maintenance monitor function Unit setting function Memory clear function Serial/GCC setting function

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Upper part of multi monitor (display portion) 30-180 (a): Multi-information display a When the engine is started, the battery voltage may lower suddenly, depending on the ambient temperature and the condition of the battery. In this case, the screen display of the machine monitor may go off for a moment. This phenomenon is not a failure, however. 30-180 Upper part of multi monitor (switch portion) [F1]: F1 Function switch [F2]: F2 Function switch [F3]: F3 Function switch [F4]: F4 Function switch [F5]: F5 Function switch [F6]: F6 Function switch a The function of each function switch is indicated by the icon which is displayed just above the function switch on the screen of the multi-information display panel (a). a If the graphic mark of a function switch is not displayed, that function switch is not working.

30-180 Outline of operator mode a The operator mode is outlined below. a For details of the operator mode, see "Structure, function and maintenance standard" or "Operation and Maintenance Manual". 1. KOMATSU logo screen When starting switch is turned ON, KOMATSU logo is displayed for two seconds. a After the KOMATSU logo is displayed for two seconds, the screen changes to the standard screen. 2. Standard screen display A clock appears at the upper row on the right of the screen and the KOMATSU logo appears at the center.

a With the standard screen displayed, press each [F] switch to go to the corresponding screen.

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Screen transition from the standard screen flow

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3. Brightness/contrast For changing settings of brightness, contrast, and luminance of the screen, select a setting screen from the standard screen. 1) With the standard screen displayed, press the [F1] switch to go to the brightness/contrast setting screen.

q q q

Press the [F5] switch to put "Contrast" in the selected state. Select the contrast with [F3] or [F4]. When the [F6] switch is pressed with the change completed, the change is entered and the screen is returned to the standard screen. 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.) 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 q

Select the brightness with pressing [F3] or [F4]. If "Brightness" only is to be changed, press the [F6] switch to enter the setting made for "Brightness" and return to the standard screen. To change "Contrast" successively, press the [F5] switch to put "Contrast" in the selected state. (In this case, the change made in "Brightness" is yet to be validated.) If the [F1] switch is pressed, the change is canceled before entering and the screen returns to the standard screen.

q q q

2) Contrast selection screen

q

Press the [F5] switch to put "Luminance" in the selected state. Select the luminance with [F3] or [F4]. When the [F6] switch is pressed with the change completed, the change is entered and the screen is returned to the standard screen. Press the [F5] switch to return to the "Brightness" selected state. (In this case, the change made in "Luminance" is yet to be validated.) If the [F1] switch is pressed, the change is canceled before entering and the screen returns to the standard screen.

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.

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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.

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 production 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.

Pressing the [F2] switch on the productivity screen changes the screen to the productivity recored screen.

Select the line of the production record to be erased on this screen. q If the [F2] switch is pressed, that particular production record is retained and the screen returns to the production record display screen. q If the [F5] switch is pressed, that particular production record is erased and the screen returns to the production record display screen.

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4) Details of fuel consumption measuring screen setting flow

5. User setting 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 downward. 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.

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
q

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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 selection. Here, "Date" is selected. q Pressing the [F6] switch displays the setting screen for selecting "Year" of the date.

q q

Select the "Set year" with [F3] or [F4]. 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. 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.) If the [F1] switch is pressed, the change is canceled before entering and the screen returns to the date setting top screen.

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3) Setting the month Set the "Month" by selecting and entering one on this screen.

7. Adjusting the time of day On the time of day setting screen, the selected 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 q

Select the "Set month" with [F3] or [F4]. When the [F6] switch is pressed with the change completed, the change is entered and the screen is returned to the date setting top screen. To change "Day" successively, press the [F5] switch to move the row and put "Day" in the selected state. (In this case, the change made in "Month" is yet to be validated.) If the [F1] switch is pressed, the change is canceled before entering and the screen returns to the date setting top screen.

Pressing the [F6] switch while "Time of day" is selected, displays the setting screen for selecting "Set time" of the time of day.

2) Setting the hour

q q

Select the "Set time" with [F3] or [F4]. 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. 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.) If the [F1] switch is pressed, the change is canceled before entering and the screen returns to the date setting top screen. WA1200-6

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3) Setting the minute Set the minutes while "Minutes" is put in the selected state.

5) Details of time of day setting flow

q q

Press the [F3] or [F4] switch to select "Set minutes". 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, "Daylight Setting Time" is not displayed. When the [F6] switch is pressed with the change completed, the change is entered and the screen returns to the date setting top screen. If the [F1] switch is pressed, the change is canceled before entering and the screen returns to the date setting top screen.

4) Setting "ON/OFF" daylight saving time

q q

Select "ON" or "OFF" with [F3] or [F4]. When the [F6] switch is pressed, the "ON/OFF" setting of the daylight saving time is entered and the screen returns to the date setting top screen. This item is not displayed when the language is set to Japanese.

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8. Inputting the user ID To set the user ID, select one on the date setting top screen. a With the standard screen on the screen, press the [F3] switch to move to the date setting top screen. 1) For inputting the user ID, select "User ID" with [F3] or [F4] on the date setting top screen.

Press the [F2] switch to erase the input value one digit at a time.

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.

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 "Numerals" input are canceled and the screen returns to the date setting top screen.
q

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3) Details of user ID input process flow

Input example: User ID 1234

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9. Language selection For setting the language, select language selection on the date setting top screen. a With the standard screen on the screen, press the [F3] switch to move to the date setting top screen. 1) To set the language, select "Language setting" with [F3] or [F4] on the date setting top screen.

3) Details of language setting flow

10. Main SCREEN select screen

Press the [F6] switch to display the language 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 consumption is displayed

q q

Select the desired language with [F3] or [F4]. If the [F6] switch is pressed, the language is entered and the screen returns to the date setting top screen. If the [F1] switch is pressed, the change is canceled before entering and the screen returns to the date setting top screen.

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11. Maintenance monitor The maintenance monitor displays names and replacement time of filters and oils. It also has a function of automatically prompting the operator to perform the necessary service procedures when the replacement time of, for example, a filter approaches. a With the standard screen displayed, press the [F4] switch to go to the maintenance monitor screen. 1) Maintenance monitor screen This screen displays replacement items of filters and oils of different types according to the replacement time.

2) Resetting the maintenance monitor After a filter or oil has been replaced with a new one, the replacement time can be reset. a On the maintenance monitor display screen, use the [F3] or [F4] switch to move to the item to be reset and press the [F6] switch to move to the reset screen that allows you to confirm whether or not replacement has been made.

Press the [F5] switch to change pages.

Select whether or not the replacement has been made on this screen. q If the [F5] switch is pressed, the screen returns to the maintenance display screen on which the replacement time has been reset. q If the [F2] switch is pressed, the screen returns to the maintenance display screen on which the replacement time remains unchanged.

q q q q

Change pages with [F2] or [F5]. Press the [F2] switch to return to the previous page. Press the [F5] switch to go to the next page. If the [F1] switch is pressed, the screen returns to the standard screen.

a To continue with the resetting of the maintenance monitor, press the [F6] switch and repeat the foregoing procedure. q If the [F1] switch is pressed, the screen returns to the standard screen.

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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 objective. 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.

12. Failure list display a The fault list display screen shows the abnormality record. For details of the failure, see the service mode. a With the standard screen on the screen, press the [F5] switch to move to the failure list display.

2] The "Productivity (load meter)" screen appears. This screen shows the number of loading sequences performed, the total amount of loaded weight, and the date when data was reset last for each loaded objective. Press the [F1] switch located at the lower left corner of the "Productivity (load meter)" screen to return to the standard screen.

q q q

Scroll the data with [F3] or [F4]. Change pages with [F2] or [F5]. If the [F1] switch is pressed, the screen returns to the standard screen.

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2) Erasure on productivity (load meter) 1] To erase "Type" data shown on the "Productivity (load meter)" screen, select the "Type" data by pressing the [F3] or [F4] switch and validate the selection using the "Select" [F6] switch.

4) Performing empty calibration 1] Select "Empty calibration" shown on the screen by pressing the [F3] or [F4] switch and validate the selection using the "Select" [F6] switch.

2] The "Productivity data erase" screen appears. Confirm the data to be erased and press the [F5] switch. The original "Productivity (load meter)" screen reappears, on which "0" is shown 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 standard screen reappears. 3) Displaying load meter menu Press the "Load meter menu" [F5] switch located at the lower right corner of the "Productivity (load meter)" screen. The "Load meter menu" screen appears. 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.

2] When the "Empty calibration" screen appears, operate the machine by following the instructions given on the screen. When the calibration is normally completed, the "Load meter menu" screen reappears.

3] If the calibration is not normally terminated, a warning screen appears. Press the [F5] switch to return to the "Load meter menu" screen and start the procedure over.

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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 reappears. 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.

2] When the "Loaded calibration" screen appears, operate the machine by following the instructions given on the screen. When the calibration is normally completed, the loaded weight entry screen appears.

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 enter the loaded weight again. 6] When the setting is normally completed, a message of setting completed appears on the screen. After verification, press the [F1] switch located at the lower left corner of the screen to return to the "Load meter menu" screen.

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7] If the calibration is not normally terminated, a warning screen appears. Press the [F5] switch to return to the "Load meter menu" screen and start the procedure over.

3] When the resetting is normally completed, a message of resetting completed appears on the screen. After verification, press the [F1] switch 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 and validate the selection using the "Select" [F6] switch.

7) Selecting display/nondisplay of load meter 1] Select "Load meter show/hide selection" 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 alternates 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.

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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 reappears.

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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.

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Service Menu 1. How to enter into the service menu

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(*1) When this screen is displayed, 1 is highlighted. Press the [F1] switch to return to the user settings screen. Each time the [F2] switch is pressed, the last input digit is erased. If no numeral is entered, the screen does not change. Press the [F3] switch to move the highlight to the left digit of the currently selected (highlighted) digit. If the numeral highlighted at present is "1", pressing [F3] highlights "0". Press the [F4] switch to move the highlight to the right digit of the currently selected (highlighted) digit. If the numeral highlighted at present is "0", 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.)

Press the [F6] switch to enter the currently displayed ID. If the ID is correct, the service menu screen appears. When it is a wrong ID, the screen remains unchanged. Press the [F2] switch to erase the incorrectly input ID. When the correct ID is input, the service menu screen appears. Or, press the [F1] switch to return to the user settings screen.

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a Two types of ID are provided: the usual ID and special ID that allows for entering the special optional menu. The entry of the special ID allows you to enter the special optional menu "Engine mode" in addition to the menus that are allowed by entry of the usual ID. Service password: 7823401300 Special password: 3287040031 (*2) When changed to this screen (Service Menu) the real-time monitor is highlighted. Press the [F3] switch to move the highlighted menu downward in sequence. (Scroll function) When the [F3] switch is pressed at the bottom item, the highlight moves to the top item. Press the [F4] switch to move the highlighted menu upward in sequence. (Scroll function) 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 standard screen. Press the [F6] switch to open the screen for the highlighted menu item. (For details, see specifications for the corresponding screen.)

2. Real-time monitor When changed to this screen (Real-time monitor (controller selection)), the main monitor is highlighted. Press the [F3] switch to move the highlighted controller downward in sequence. When the [F3] switch is pressed at the bottom item, the highlight moves to the top item. Press the [F4] switch to move the highlighted controller 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 service menu selecting screen. Press the [F6] switch to open the real-time monitor screen for the highlighted controller. (For details, see specifications for the corresponding screen.) REAL TIME MONITOR screen (for selection of controller)

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Press the [F1] switch to return to the real-time monitor (controller selection) selecting screen. Press the [F2] switch to go to the next page. Press the [F5] switch to go to the previous page. When the [F3] switch is pressed while the value is not held, the displayed value is held. (The button indication changes to "RESET".) When the [F3] switch is pressed while the value is held, the held value is released. (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 monitor)

As the engine has 16 cylinders, in order to check the exhaust gas temperature of 16 cylinders at the same time, a special screen " Exhaust gas temperature list" is provided. If the menu of "6 ITEMS" is selected, desired cylinders can be specified (each cylinder has an ID) to check the exhaust gas temperature of individually. To check exhaust gas temperature of all cylinders at once, use the real time monitor function of the engine controller.

When changed to this screen (Real-time monitor (6ITEMS)), the first row is highlighted. Press the [F3] switch to move the highlighted row downward in sequence. When the [F3] switch is pressed at the bottom item, the highlight moves to the top item. Press the [F4] switch to move the highlighted 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. (The button indication changes to "PAUSE".) Press the [F6] switch to open the ID input screen for the highlighted row.

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6 ITEMS screen

Press the [F1] switch to abort ID input and return to the previous screen. (ID returns to the value that was held before change to this screen.) Press the [F2] switch to move the highlighted input box to the previous box. If the foremost place is highlighted, the highlighted 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". Press the [F5] switch to move the highlighted 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 monitoring 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

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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 No. screen ID No. Item Remarks unit (Example of display) (*) page
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 1 1 2 2 2 2 2 3 3 3 3 3 3 4 4 5 5 5 5 5 5 6 6 7 7 7 7 7 7 20200 20221 20222 01001 40012 04202 04200 04103 04408 04409 04401 04404 30201 30204 04302 40200 06001 06003 40400 40402 40500 40501 40600 40800 40900 40901 40902 40903 40904 40925 MONITOR PROG P/N VERSION(APP) VERSION(DATA) ENGINE SPEED VEHICLE SPEED FUEL SENSOR FUEL SENSOR COOLANT TEMP T/C TEMP T/C TEMP HYD. OIL TEMP HYD. OIL TEMP BRAKE OIL TEMP BRAKE OIL TEMP ALTERNATOR R SMALL LAMP BOOM ANGLE BOOM ANGLE BOOM BOTTOM PRESSURE BOOM BOTTOM PRESSURE BOOM HEAD PRESSURE BOOM HEAD PRESSURE CAL PRESSURE MEASURED LOAD D-IN 0-7 D-IN 8-15 D-IN 16-23 D-IN 24-31 D-IN 32-39 D-OUT 0-3 ------1 rpm 0.1 km/h 1% 0.01V 1 C 1 C 0.01 V 1 C 0.01 V 1 C 0.01 V 0.1 V 0.1 V 1 deg. 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.01 t ------------10-digit part No. is displayed. 01010101 01010101 0 to 4000 0.0 to 50.0 0 to 100 0.0 to 5.0 40 to 210 24 to 131 0.00 to 5.00 24 to 131 0.00 to 5.00 24 to 131 0.00 to 5.00 0.0 to 30.0 0.0 to 30.0 -90 to 90 0.00 to 5.00 0.00 to 50.00 0.00 to 5.00 0.00 to 50.00 0.00 to 5.00 0.00 to 50.00 0.00 to 50.00 01010101 01010101 01010101 01010101 01010101 01010101 Source: engine controller Source: transmission controller

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KOMTRAX Plus controller Monitor No. screen ID No. page

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 1 1 1 1 2 2 2 2 3 3 3 3 3 3 4 4 4 4 5 5 5 6 37501 37504 99701 99700 04304 99703 99702 99705 99704 32601 32602 32603 32604 29700 29701 92800 92802 92801 92803 40303 40304 40305 40944

Item
AMBIENT AIR TEMP AMBIENT AIR TEMP PPC OIL PRESSURE PPC OIL PRESSURE CHARGED AMOUNT T/M MAIN PRESSURE T/M MAIN PRESSURE T/M LUB PRESSURE T/M LUB PRESSURE T/C IN PRESSURE T/C IN PRESSURE TC OUT PRESSURE TC OUT PRESSURE S/T PUMP PRESSURE S/T PUMP PRESSURE F BRAKE OIL PRESSURE F BRAKE OIL PRESSURE R BRAKE OIL PRESSURE R BRAKE OIL PRESSURE BATTERY LEVEL 1 BATTERY LEVEL 2 BATTERY LEVEL 3 D-IN 0-7

Data unit
1 C 0.01 V 0.01 MPa 0.01 V 0.1 V 0.01 MPa 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.01 V 0.01 MPa 0.0 1V 0.01 MPa 0.01 V

Display range of data (Example of display) (*)

-30 to 100 0.00 to 5.00 0.00 to 50.00 0.00 to 5.00 0.0 to 30.0 0.00 to 50.00 0.00 to 5.00 0.00 to 50.00 0.00 to 5.00 0.00 to 50.00 0.00 to 5.00 0.00 to 50.00 0.00 to 5.00 0.00 to 50.00 0.00 to 5.00

Remarks

0.01 MPa 0.00 to 50.00 0.01 V 0.00 to 5.00

0.01 MPa 0.00 to 50.00 0.01 V 0.01 V 0.01 V 0.01 V --0.00 to 5.00 0.00 to 5.00 0.00 to 5.00 0.00 to 5.00 01010101 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero. 01010101 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero. 010 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero. 0101 ["1" or "0" in the corresponding digit (number)] 1: output signal ON, 0: output signal OFF, unused part is also zero. 0101 ["1" or "0" in the corresponding digit (number)] 1: input signal ON, 0: input signal OFF, unused part is also zero.

Outputs the input signals intact of D_IN_0 to D_IN_7

24

40945

D-IN 8-15

---

Outputs the input signals intact of D_IN_8 to D_IN_15 Outputs the input signals intact of D_IN_16 to D_IN_18 Outputs the output signals intact of D_OUT_0 to D_OUT_3 Outputs the input signals intact of SEL_0 to SEL_3

25

40972

D-IN 16-18

---

26

40948

D-OUT 0-3

---

27

40947

D=SOL 0-3

---

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Engine controller Monitor No. screen ID No. page

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 1 1 1 1 1 2 2 2 2 3 4 4 4 5 5 5 5 6 6 6 6 7 7 7 7 8 8 8 8 01002 04102 42700 36400 42801 36501 37200 43800 37400 37300 42614 42615 42616 42617 42618 42619 42620 42621 42622 42623 42624 42625 42626 42627 42628 42629 42630 42631 42632

Item
ENGINE SPEED COOLANT TEMP ENGINE OIL TEMP COMMON RAIL PRESSURE BLOW BY PRESSURE BOOST PRESSURE ENGINE OIL PRESSURE ENGINE OIL LEVEL ATMOSPHERE PRESSURE FUEL CONSUMP EXHAUST GUS TEMP EXHAUST GUS TEMP AVERAGE EXHAUST GUS TEMP R AVERAGE EXHAUST GUS TEMP L AVERAGE EXHAUST GUS TEMP R1 EXHAUST GUS TEMP R2 EXHAUST GUS TEMP R3 EXHAUST GUS TEMP R4 EXHAUST GUS TEMP R5 EXHAUST GUS TEMP R6 EXHAUST GUS TEMP R7 EXHAUST GUS TEMP R8 EXHAUST GUS TEMP L1 EXHAUST GUS TEMP L2 EXHAUST GUS TEMP L3 EXHAUST GUS TEMP L4 EXHAUST GUS TEMP L5 EXHAUST GUS TEMP L6 EXHAUST GUS TEMP L7 EXHAUST GUS TEMP L8

Data unit
1 rpm 1 C 1 C 0.01 MPa 0.01 kPa 1 kPa 1 kPa --1 kPa 0.1 l/h 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C 1 C

Display range of data (Example of display) (*)

0 to 8031 -273 to 1735 40 to 210 0 to 250.00 -250 to 251.99 0 to 500 0 to 1000 OK (normal), NG (defective) 0 to 125 0.0 to 3212.8 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735 -273 to 1735

Remarks
CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 CM850 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.

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Transmission controller No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Monitor screen page

1 1 1 2 2 2 2 2 3 3 3 3 4 4 4 4 4 4 5

ID No.
20201 20223 20224 41600 92502 31400 93900 01008 41203 41201 41202 93700 93600 93601 93602 93603 92400 92401 95500

Item
T/M PROG P/N T/M VERSION(APP) T/M VERSION(DATA) ENGINE MODE Mod/C SPEED: OUT T/M SPEED: OUT TIRE FR SPEED ENGINE SPEED T/M CUT OFF SET PRESSURE T/M CUT OFF PRESSURE T/M CUT OFF PRESSURE T/C SPEED RATIO T/M OIL TEMP T/M OIL TEMP T/M OIL TEMP2 T/M OIL TEMP2 MOD/C PRESSURE MOD/C PRESSURE THROTTLE LOCK A THROTTLE LOCK B

Data details
Part number of mass production software Software version (software logic part version) Software version (software data part version)

Data unit (and range)

Remarks

10-digit number (78**-**-****) According to software version According to software version 0: Torque curve H Engine mode for engine output 1: Torque curve M control 2: Torque curve L x 1 [min-1] Modulation clutch output speed (0 to 32767 [min-1]) x 1 [min-1] Transmission output shaft speed (0 to 32767 [min-1]) x 1 [min-1] Front left tire speed (0 to 32767 [min-1]) x 1 [min-1] Engine speed (0 to 32767 [min-1]) Reduced transmission cutoff set x 0.001 [MPa] pressure (IN pressure) (0 to 5 [MPa]) x 0.001 [MPa] Reduced brake oil pressure (0 to 5 [MPa]) x 0.001 [V] Input voltage of brake pressure (0 to 5 [V]) x 1 [%] Torque converter speed ratio (0 to 100 [%]) Transmission oil temperature x 1 [ C] (A_IN_1) (0 to 150 [ C]) Input voltage of transmission oil x 1 [mV] temperature (A_IN_1) (0.00 to 5.00 [V]) Transmission oil temperature x 1 [ C] (A_IN_3) (0 to 150 [ C]) Input voltage of transmission oil x 1 [mV] temperature input (A_IN_3) (0.00 to 5.00 [V]) Oil pressure equivalent to modula- x 1 [MPa] tion clutch pressure input (A_IN_7) (0.00 to 5.00 [MPa]) Voltage value of modulation clutch x 1 [mV] pressure input (A_IN_7) (0.00 to 5.00 [V]) Status of input signal 0: RPM set switch OFF 1: PRM set switch ON

For WA1200, 1: Torque curve M is not used.

Because of detection at analog port Because of detection at analog port

20

95501

21 22 23 24 25 26 27 28 29 30 31

5 6 6 6 6 7 7 7 7 7 7

44201 94000 94001 40014 40015 31602 31603 31604 31608 31606 31640

0: PRM set auto-deceleration switch OFF Status of input signal 1: PRM set auto-deceleration switch ON THROTTLE LIMIT Command value for lower limit of x 0.1 [%] LO throttle position (0.0 to 100.0 [%]) x 1 [%] TRACTION DIAL Set value of traction dial (0 to 100 [%]) Input voltage of set value from trac- x 1 [mV] TRACTION DIAL tion dial (0.00 to 5.00 [V]) x 1 [km/h] SPEED DIAL Set value of speed control dial (3 to 12 [km/h]) Input voltage of set value from x 1 [mV] SPEED DIAL speed control dial (0.00 to 5.00 [V]) Current value of ECMV output x 1 [mA] ECMV 1 DIR command to 1st clutch (0 to 1000 [mA]) Current value of ECMV output x 1 [mA] ECMV 2 DIR command to 2nd clutch (0 to 1000 [mA]) Current value of ECMV output x 1 [mA] ECMV 3 DIR command to 3rd clutch (0 to 1000 [mA]) Current value of ECMV output x 1 [mA] ECMV F DIR command to FWD clutch (0 to 1000 [mA]) Current value of ECMV output x 1 [mA] ECMV R DIR command to REV clutch (0 to 1000 [mA]) ECMV MOD/C Current value of ECMV output x 1 [mA] DIR command to modulation clutch (0 to 1000 [mA])

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No.
32 33 34 35 36 37 38 39 40 41

Monitor screen page

8 8 8 8 8 9 9 9 9 9

ID No.
41802 41803 41804 41808 41806 40905 40906 40907 40908 40942

Item
FILL TIME 1 FILL TIME 2 FILL TIME 3 FILL TIME F FILL TIME R D-IN 0-7 D-IN 8-15 D-IN 16-23 D-IN 24-31 D-IN 32-39

Data details
Fill time of 1st clutch (at last gear shifting) Fill time of 2nd clutch (at last gear shifting) Fill time of 3rd clutch (at last gear shifting) Fill time of FWD clutch (at last gear shifting) Fill time of REV clutch (at last gear shifting) Status of input signal Status of input signal Status of input signal Status of input signal Status of input signal ON/OFF output from SOL_OUT0 to 7. '0' indicates that drive current is output. ON/OFF output from SOL_OUT8 to 11B. '0' indicates that drive current is output. ON/OFF output from SOL_OUT2 to 3, SW_OUT0 to 1, and BATT_RY_OUT. '0' indicates that drive current is output.

Data unit (and range)

x 0.01 [sec] (0 to 2.55 [sec], 0: no fill) x 0.01 [sec] (0 to 2.55 [sec], 0: no fill) x 0.01 [sec] (0 to 2.55 [sec], 0: no fill) x 0.01 [sec] (0 to 2.55 [sec], 0: no fill) x 0.01 [sec] (0 to 2.55 [sec], 0: no fill) 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 1: ON, 0: OFF(OPEN) Corresponds to each bit 11-digit number indicates learning flags for clutches in the following order: [FFFRRR11123] Learned: 1, Not learned: 0 F, R, and 1st clutches have 3 flags depending on learning conditions starting from the left: engine speed Z 875 rpm, 875 to 1200 rpm, and engine speed X 1200 rpm Learning flags for 2nd and 3rd clutches do not depend on engine speed. x 0.1 [deg] (-25.0 to 25.0 [deg]) x 1 [mV] (0.00 to 5.00 [V]) x 0.1 [deg] (-25.0 to 25.0 [deg]) x 1 [mV] (0.00 to 5.00 [V]) x 1 [MPa] (0.00 to 50.00 [MPa]) x 1 [mV] (0.00 to 5.00 [V]) x 1 [MPa] (0.00 to 50.00 [MPa]) x 1 [mV] (0.00 to 5.00 [V])

Remarks

Fix to 0 for unused ports 33 to 39.

42

10

40949

D-OUT 0-7

43

10

40950

D-OUT 8-15

44

10

40951

D-OUT 16-23

45

11

94100

Status of trigger time initial learning Trigger Learning flag for each clutch Flag [F, F, F, R, R, R, 1, 1, 1, 2, 3]

11-bit data in order of FFFRRR11123 is displayed on multi-function monitor.

46 47 48 49 50 51 52 53

11 11 11 11 12 12 12 12

32900 32902 32904 32905 35500 35504 35501 35505

ANGLE SENSOR(FR) ANGLE SENSOR(FR) ANGLE SENSOR(LR) ANGLE SENSOR(LR) BRAKE OIL PRESSURE F BRAKE OIL PRESSURE F BRAKE OIL PRESSURE R BRAKE OIL PRESSURE R

Inclination angle equivalent to pitch angle sensor input (A_IN_9) Voltage value of pitch angle sensor input (A_IN_9) Inclination angle equivalent to pitch angle sensor input (A_IN_9) Voltage value of pitch angle sensor input (A_IN_9) Oil pressure value equivalent to brake oil pressure sensor input (A_IN_15) Voltage value of brake oil pressure sensor input (A_IN_15) Oil pressure value equivalent to brake oil pressure sensor input (A_IN_16) Voltage value of brake oil pressure sensor input (A_IN_16)

Value not filtered

Value not filtered

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Work equipment controller No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Monitor screen page

1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 5 5

ID No.
20202 20225 20226 41900 41909 41901 41910 41902 41911 41903 41912 42000 42001 42002 42003 06002 06005

Item
BBC PROG P/N

Data details

Data unit (and range)

10-digit number (78**-**-****) According to software version According to software version x 1 [mA] (0 to 1000 [mA]) x 1 [mA] (0 to 1000 [mA]) x 1 [mA] (0 to 1000 [mA]) x 1 [mA] (0 to 1000 [mA]) x 1 [mA] (0 to 1000 [mA]) x 1 [mA] (0 to 1000 [mA]) x 1 [mA] (0 to 1000 [mA]) x 1 [mA] (0 to 1000 [mA]) x 0.001 [V] (0.00 to 5.00 [V]) x 0.001 [V] (0.00 to 5.00 [V]) x 0.001 [V] (0.00 to 5.00 [V]) x 0.001 [V] (0.00 to 5.00 [V]) x 0.1 [deg] (-60.0 to +60.0 [deg]) x 0.001 [V] (0.00 to 5.00 [V]) 0 to 256000 (in increments of 1000 operations) 0 to 256000 (in increments of 1000 operations) x 1 [cc/rev] (150 to 830 [cc/rev]) x 0.1 [deg] (-60.0 to +60.0 [deg]) x 0.001 [V] (0.00 to 5.00 [V]) x 0.1 [deg] (-60.0 to +60.0 [deg]) x 0.001 [V] (0.00 to 5.00 [V]) x 1 [mA] (0 to 1000 [mA]) x 0.01 [MPa] (0 to 56.3 [MPa]) x 0.001 [V] (0 to 5 [V]) x 0.01 [MPa] (0 to 50 [MPa]) x 0.001 [V] (0 to 5 [V]) x 0.1 [deg] (0.0 to +120.0 [deg])

Remarks

Part number of mass production software Software version (software BBC VERSION (APP) logic part version) Software version (software BBC VERSION (DATA) data part version) Command current value to lift RAISE EPC DIR 1 arm RAISE EPC Command current value to lift RAISE EPC DIR 2 arm RAISE EPC Command current value to lift LOWER EPC DIR 1 arm LOWER EPC Command current value to lift LOWER EPC DIR 2 arm LOWER EPC Command current value to TILT EPC DIR 1 bucket TILT EPC Command current value to TILT EPC DIR 2 bucket TILT EPC Command current value to DUMP EPC DIR 1 bucket DUMP EPC Command current value to DUMP EPC DIR 2 bucket DUMP EPC Input voltage value from lift BOOM POT1 arm lever potentiometer 1 Input voltage value from lift BOOM POT2 arm lever potentiometer 2 Input voltage value from BUCKET POT1 bucket lever potentiometer 1 Input voltage value from BUCKET POT2 bucket lever potentiometer 2 BOOM ANGLE BOOM ANGLE Calculated lift arm angle Input voltage value from lift arm angle sensor potentiometer The number of lift arm lever operations expressed in increments of 1000 operations The number of bucket lever operations expressed in increments of 1000 operations Calculated pump delivery

18

42100

BOOM LEVER

19 20 21 22 23 24 25 26 27 28 29 30

5 5 6 6 6 6 6 7 7 7 7 7

42101 94600 94300 94301 94400 94401 41908 94700 94701 40401 40402 94800

BUCKET LEVER PUMP FLOW AJSS LEVER

AJSS lever angle equivalent to AJSS lever potentiometer input Input voltage value from AJSS AJSS LEVER lever potentiometer Frame angle equivalent to FRAME ANGLE AJSS frame potentiometer input Input voltage value from AJSS FRAME ANGLE frame potentiometer Command current to AJSS AJSS EPC DIR EPC Reduced loader pump presLO PUMP PRESSURE sure Input voltage value of loader LO PUMP PRESSURE pump pressure BOOM BOTTOM Reduced lift arm cylinder botPRESSURE tom pressure BOOM BOTTOM Input voltage value of lift arm PRESSURE cylinder bottom pressure. Deviation between AJSS S/T DEFLECTION frame potentiometer angle and AJSS lever angle

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No.
31 32 33 34 35

Monitor screen page

7 8 8 8 8

ID No.
94900 40910 40911 40912 40913

Item
WORK FLAG D-IN 0-7 D-IN 8-15 D-IN 16-23 D-IN 24-31

Data details
Status of digging-in-progress flag Status of input signal Status of input signal Status of input signal Status of input signal

Data unit (and range)

1: ON (when in digging 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 1: ON, 0: OFF(OPEN) Applied to each bit

Remarks

36

40961

D-IN 32-39

Status of input signal

Input signals 33-39 without port are fixed at 0 to simplify communication information.

37

40952

D-OUT 0-7

38

40953

D-OUT 8-15

39

40954

D-OUT 16-23

ON/OFF output from SOL_OUT0 to 7. '0' indicates that drive current is output. ON/OFF output from SOL_OUT8 to 11B. '0' indicates that drive current is output. ON/OFF output from SIG_OUT2 to 3, HSW_OUT0 to 1, and BATT_RY_OUT '0' indicates that drive current is output.

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

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3. Pm Clinic function The machine monitor uses signals from the sensors installed at different parts of the machine to permit Pm Clinic function that checks the engine speed and oil pressures at different parts of the machine. The monitor also has a function of retaining the fluctuation data, as in the real-time monitor. a When the [F6] switch is pressed with the service ID input, the service menu selecting screen appears.

1) Pm Clinic menu The Pm Clinic display is accessed through service menu selection, showing the engine speed and oil pressures at different parts of the machine. 1] Pm Clinic item screen (1/4) Displays the engine speed, oil pressure, oil quantity, and coolant temperature.

q q q

Select Pm Clinic by pressing [F3] or [F4]. Press the [F6] switch to move to the Pm Clinic menu screen. Press the [F1] switch to return to the date setting top screen.

a The Pm Clinic screen is changed in the same manner as with the real-time monitor and the description for it is omitted. 2] Pm Clinic item screen (2/4) Displays are information on the engine speed, blow-by pressure, boost pressure, exhaust gas temperature, atmospheric temperature, and fuel rail pressure.

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3] Pm Clinic item screen (3/4) Displays the information on the torque converter oil temperature, inlet pressure, outlet pressure, transmission main pressure, lubricating pressure, and MOD (modulation) pressure.

2) Details of Pm Clinic display flow

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.

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4. Abnormality record display function The machine monitor records failure that occurred in the past or that are occurring at present. a When the [F6] switch is pressed with the service ID input, the "SERVICE MENU SELECT" screen appears.

Press the [F6] switch on a failure item to put it in nondisplay mode. Once put in the nondisplay mode, the record for this item will not be displayed again. (However, the KOMTRAX Plus controller memory will be kept.)

Select the abnormality record ("Failure History") with [F3] or [F4]. q Press the [F6] switch to move to the abnormality record screen. q If the [F1] switch is pressed, the screen returns to the date setting screen. 1) Abnormality record display The abnormality record displays such information 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

q q q

Scroll the item with [F3] or [F4]. Skip over three items to display every fourth one with [F2] or [F5]. If the [F1] switch is pressed, the screen returns to the service menu select screen.

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2] Information displayed on "Abnormality Record" screen The abnormality record display screen shows failure information on the screen as follows. (a): Failure occurring in reverse chronological order (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 machine monitor can record, see Troubleshooting, "Fault code list". 2) Abnormality record menu a For the procedure to erase the abnormality record, see 7. Memory clear function.

5. Snapshot function The snapshot function can store data in the KOMTRAX Plus controller for use in Pm Clinic, and inspection and adjustments. a When the [F6] switch is pressed with the service ID input, the service menu selecting screen appears.

q q q

Select the Snapshot Trigger with [F3] or [F4]. Press the [F6] switch to move to the snap shot screen. Press the [F1] switch to return to the date setting 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 q

Press the [F6] switch to move to the next Snapshot screen (2/6). If the [F1] switch is pressed, the screen returns to the service menu selecting screen.

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2] Snapshot display screen (2/6) The screen prompts you to determine whether the Snapshot is to be started or not.

4] Snapshot display screen (4/6) Snapshot is performed with a message of Snapshot being run and the elapsed time appearing on the screen.

q q

Press the [F5] switch to move to the Snapshot starting screen. If the [F2] switch is pressed, the screen returns to the previous screen.

Pressing the [F1] switch stops the Snapshot, showing the Snapshot screen 6].

3] Snapshot display screen (3/6) Performance of Snapshot is started with a message of Snapshot being run and the elapsed time appearing on the screen.

5] Snapshot display screen (5/6) The snapshot ending screen appears.

Pressing the [F1] switch stops the Snapshot, showing the Snapshot screen 1].

a End of Snapshot If the [F6] switch is pressed, the screen returns to the Snapshot screen 2]. q If the [F1] switch is pressed, the screen returns to the service menu selecting screen.
q

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6] Snapshot display screen (6/6) Snapshot cancel display screen

6. Adjustment Menu 1) Adjustment menu selecting screen When this screen (adjustment screen) appears, the Load Meter is highlighted. Press the [F3] switch to move the highlighted menu downward in sequence. Press the [F4] switch to move the highlighted 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 If the [F6] switch is pressed, the screen returns to the Snapshot screen 2]. q If the [F1] switch is pressed, the screen returns to the service menu selecting screen.
q

2) Details of Snapshot menu flow 2) Adjustment Menu (1) Load Meter 1] When this screen (Adjustment screen) appears, the boom angle sensor (upper) adjustment is highlighted. Press the [F3] switch to move the highlighted menu downward in sequence. Press the [F4] switch to move the highlighted 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.

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2] Boom angle sensor (upper) 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 to the main monitor. A message appears according to the command (setting completed or setting failed) from the main monitor. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway Press the [F1] switch to return to the Adjustment (1) load meter 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 to the main monitor. A message appears according to the command (setting completed or setting failed) from the main monitor. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway

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 Special functions of multi monitor

Press the [F4] switch to increment the value by 1[t]. q Threshold setting range Metric tons: 20 to 99 [t] US tons: 22 to 99 [t] If 99 [t] is specified in metric tons or US tons, a special mode is set in which no alarm is issued for any payload. q When the metric tons or US tons is changed, the previous setting value is stored in memory and a value is displayed corresponding to the set tonnage. 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.

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). After the message is confirmed, press the [F5] switch to go 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 Special functions of multi monitor

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.

3) Adjustment (AJSS) 1] Adjustment Menu (2) AJSS screen Select AJSS on the Adjustment screen and press the [F6] switch.

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 to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway Press the [F1] switch to return to the Adjustment (2) AJSS screen.

When this screen (Adjustment screen) appears, the AJSS neutral position adjustment is highlighted. Press the [F3] switch to move the highlighted menu downward in sequence. Press the [F4] switch to move the highlighted 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.

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3] AJSS EPC output current adjustment screen When this screen appears, the adjustment current value 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 [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 equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. After the transmission of the signal, the adjustment current value is updated according to a signal from the work equipment controller.

A change of the numeric value is displayed according to the work equipment 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 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. 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 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 signal to the work equipment controller. After the transmission of the signal, the pattern number is updated according to a signal from the work equipment controller.

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4) Adjustment (work equipment) 1] Adjustment Menu (3) Work Equipment screen Select work equipment on the Adjustment screen and press the [F6] switch.

When this screen (Adjustment screen) appears, the boom angle sensor (upper) adjustment (work equipment controller) is highlighted. Press the [F3] switch to move the highlighted menu downward in sequence. (Scroll function) Press the [F4] switch to move the highlighted menu upward in sequence. (Scroll function) Press the [F1] switch to return to the Adjustment screen. Press the [F6] switch to open the screen for the highlighted menu item.

2] Boom angle sensor (upper) adjustment (for work equipment controller) 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 to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway

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3] Boom Raise Lever/ EPC Dead Band 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 to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is 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 adjustment q Boom raise EPC current adjustment

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)

4] Boom Lower Lever/ EPC Dead Band 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 to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway [Special notes]

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Adjustment item q Boom lever lower detent position adjustment q Boom lower EPC current adjustment

5] Bucket Tilt Lever/ EPC Dead Band 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 to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is 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 Bucket tilt detent position adjustment q Bucket tilt EPC current adjustment

6] Bucket Dump Lever/ EPC Dead Band 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 to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway [Special notes] One type of adjustment is available from this screen. Adjustment item q Bucket dump EPC current adjustment

7] Boom Lever Pattern Change 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 a boom lever pattern change signal to the work equipment controller. After the transmission of the signal, the pattern number is updated according to a signal from the work equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations.

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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. "-" is displayed until information is notified for the first time after the screen appears. Press the [F6] switch to send a bucket lever pattern change signal to the work equipment controller. After the transmission of the signal, the pattern number is updated according to a signal from the work equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations.

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 notified 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 equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. Press the [F4] switch to send a DOWN signal to the work equipment controller. After the transmission of the signal, the numeric value (%) is updated according to a signal from the work equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations.

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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). If a communication failure with the controller lasts for 0.5 second or more during adjustment, the screen returns to the service menu screen without displaying the abnormal end screen.

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5) Adjustment (T/M controller) 1] Adjustment Menu (4) T/M screen When this screen (Adjustment screen) appears, the T/M trigger initial learning data reset is highlighted. Press the [F1] switch to return to the Adjustment screen. Press the [F6] switch to open the screen for the highlighted menu item.

3] T/M trigger initial learning data reset screen (setting completed screen) A message appears according to the command (finished or wrong value) from the T/M controller. When the setting is completed: Finished When the setting failed: Wrong Value Until a command is received: Setting is underway

2] T/M trigger initial learning data reset screen Press the [F2] switch to return to the Adjustment (4) T/M screen without resetting the data. Press the [F5] switch to send a reset signal to the T/M controller and the setting completed screen will be displayed. A reset condition is checked with the real-time monitor.

4] TM-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). After the message is confirmed, press the [F5] switch to go to the Adjustment (4) TM screen. If a communication failure with the controller lasts for 0.5 second or more during adjustment, the screen returns to the service menu screen without displaying the abnormal end screen.

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7. Option setting screen (1/2) 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.) Press the [F3] switch to move the highlighted 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 selection. Press the [F2] switch to change option setting pages.

Option setting screen (2/2)

Default Boom specification Types of tire Tire size correction Economy indication lamp Triple prohibited Wall surface digging prevention Tire slip prevention control Dump approach control Travel speed control Engine mode STD STD 0% ADD NO ADD ADD ADD ADD TYPE 1 AUTO Hi Lift OPT 1

Choices Ext Hi Lift OPT 2

12%(2% increments) NO ADD ADD NO ADD NO ADD NO ADD TYPE 2 P fixed E fixed

* The engine mode appears only if a special ID is entered during entry of the service ID.

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8. Maintenance monitor function The maintenance monitor function displays the remainder time relative to a specified value for each replacement time of filters and oils of different types according to the maintenance item. Input of maintenance ID permits changing of the interval time. a When the [F6] switch is pressed with the service ID input, the service menu selecting screen appears.

q q q

Select the maintenance item with [F3] or [F4] switch. Change pages with [F2] or [F5] switch. Press the [F6] switch to move to the maintenance monitor setting screen. (Input the maintenance interval.) If the [F1] switch is pressed, the screen returns to the service menu.

2] 1000 h maintenance screen Displays the maintenance 1000 h items.

q q q

Select the maintenance monitor with [F3] or [F4]. Press the [F6] switch to move to the maintenance monitor screen. Press the [F1] switch to return to the date setting top screen.

a The maintenance item screen is changed in the same manner and the description for it will be omitted. 3] 2000 h maintenance screen (1/2) 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.

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4] 2000 h maintenance screen (2/2) Displays the maintenance 2000 h items.

2) Details of the maintenance monitor display 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.

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 maintenance monitor setting. q Press the [F6] switch to enter the maintenance monitor setting time. q Press the [F1] switch to move to the item screen from which the maintenance monitor setting screen was accessed.
q

*1: Returns to the item screen from which the maintenance monitor setting screen was accessed.

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9. Setting the unit 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.

3) Details of unit setting flow

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 q

Select "SI" with [F3] or [F4]. If the [F6] switch is pressed, the unit selected is entering and the screen returns to the service menu selecting screen. If the [F1] switch is pressed, the change made is canceled and the screen returns to the service menu selecting screen.

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10. Memory clear function The memory clear function erases data stored in the KOMTRAX Plus, including the abnormality record, maintenance, trend, load map, and Snapshot. a When the [F6] switch is pressed with the service ID input, the "SERVICE MENU SELECT" screen appears.

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 memory clear ID. q Press the [F6] switch to enter the memory clear ID, showing the memory clear item screen.
q

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 q q

Select memory clear with [F3] or [F4]. Press the [F6] switch to move to the memory clear ID entry screen. If the [F1] switch is pressed, the screen returns to the date setting screen.
q q q

1) Memory clear menu 1 The memory clear function allows each individual type of data stored in the KOMTRAX Plus, including the abnormality record, maintenance, trend, load map, and Snapshot, to be erased individually from the memory with the entry of the memory clear ID. 1] Memory clear ID entry screen Screen on which the memory clear ID is entered to move to the corresponding item

Press the [F3] switch to move to the memory clear maintenance item. Press the [F4] switch to move to the memory clear Snapshot item. If the [F1] switch is pressed, the screen returns to the service menu selecting screen.

3] Memory clear screen (showing items)

q q

Select the memory clear item with [F3] or [F4]. If the [F1] switch is pressed, the screen returns to the service menu selecting screen.

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2) Memory clear menu 2 To erase data from memory, move through items with the [F3] or [F4] switch on the memory clear screen, and select the item to be erased with the [F6] switch, thereby displaying the memory clear screen. 1] Abnormality record memory ("Failure 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

If the [F5] switch is pressed, the abnormality record is erased and the screen returns to the memory clear screen.

2]-1 Maintenance memory clear Select maintenance with [F3] or [F4] on the maintenance clear screen.

Press the [F6] switch to move to the maintenance 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 q

Select memory clear item abnormality record with [F3] or [F4]. Press the [F6] switch to move to the abnormality record erase confirm screen.

1]-2 Abnormality record memory clear confirm screen This screen prompts you to determine whether to erase the abnormality record or not. Confirm erasure with the [F2] or [F5] switch.

If the [F5] switch is pressed, the maintenance memory is erased and the screen returns to the memory clear screen. If the [F2] switch is pressed, that maintenance memory is not erased and the screen returns to the memory clear screen.

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3]-1 Trend memory clear Select trend with [F3] or [F4] on the memory clear screen.

4]-1 Load map memory clear Select the load map with [F3] or [F4] on the memory clear screen.

Press the [F6] switch to move to the trend memory clear screen.

Press the [F6] switch to move to the load map memory clear confirm screen.

3]-2 Trend memory clear confirm screen This screen prompts you to determine whether to erase trend memory or not. Confirm erasure with the [F2] or [F5] switch.

4]-2 Load map memory clear confirm screen This screen prompts you to determine whether to clear load map memory or not. Confirm erasure with the [F2] or [F5] switch.

If the [F5] switch is pressed, the trend memory is erased and the screen returns to the memory clear screen. If the [F2] switch is pressed, that trend memory is not erased and the screen returns to the memory clear screen.

If the [F5] switch is pressed, the load map memory is erased and the screen returns to the memory clear screen. If the [F2] switch is pressed, the load map memory is not erased and the screen returns to the memory clear screen.

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5]-1 Snap shot memory clear Select the snap shot with [F3] or [F4] on the memory clear screen.

Press the [F6] switch to move to the snap shot memory clear confirm screen.

5]-2 Snap shot clear confirm screen This screen prompts you to determine whether to erase snap shot memory or not. Confirm erasure with the [F2] or [F5] switch.

If the [F5] switch is pressed, the snap shot memory is erased and the screen returns to the memory clear screen. If the [F2] switch is pressed, the snap shot memory is not erased and the screen returns to the memory clear screen.

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2) Details of memory clear menu flow

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11. Serial/GCC number setting function The serial/GCC number setting function allows machine serial number and other information to be displayed on the monitor. a When the [F6] switch is pressed with the service ID entered, the service menu selecting screen appears.

Caution and warning display function during op30-234 eration The function displays machine failure information on the monitor screen during operation as a caution or warning. a If a failure occurs in the machine during operation 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 operation, 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 q

Select the Serial/GCC No. Setting with [F3] or [F4]. Press the [F6] switch to move to the serial/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.

If the [F1] switch is pressed, the service menu selecting screen reappears. a No serial number input screen is available from the multi monitor.

Press the [F1] or [F4] switch to return to the screen that was displayed before the

warning screen.

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When the [F4] switch is pressed, the warning screen is displayed again 2 minutes later. When the [F1] switch is pressed, the warning is cleared (however, the KOMTRAX Plus memory is kept). When the [F3] switch is pressed, the warning display is held. When the [F3] switch is pressed again, the screen will be automatically switched.

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Pm Clinic Outline of measurement procedure for Pm Clinic

Pm Clinic

Outline of measurement procedure for Pm Clinic

The following three ways are available for the masurement procedure for PM clinic of WA1200-6. a Basically, apply measurement procedure 1 or 2. 1. Measurement procedure by multi monitor Read the data from the Pm clinic screen by using "Pm Clinic function" of the multi monitor.

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3. Measurement procedure by downloading data in KOMTRAX Plus controller Connect a personal computer to the KOMTRAX Plus controller and perform the quick Pm Clinic with the multi monitor, and then download the Pm Clinic data to the personal computer. a The following tools are necessary to this measurement procedure.
Symbol ZB Part No. 799-608-3211 1 799-608-3220 Commercially 2 available Part name CD-ROM Wiring harness Note type PC (OS: Windows98/2000/Me/XP)

2. Measurement procedure by stopwatch, scale, etc. Take each measurement by using a stopwatch, scale, etc.

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Preparation for measurement for Pm Clinic

k

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For safety reasons, park the machine on a level ground, and chock the wheels to prevent the machine from moving.

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 temperature. 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 servicing procedures and conditions.

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Pm Clinic Pm clinic service

Pm clinic service
User name Location Date of delivery Year Month Day / / User name Machine serial No. Engine serial No.

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Specifications Tire: Front/Rear T 55.5/80-57-68PR(L5) T 66/65-57-62PR(L5) T Bucket m3 (cu.yd) T 20.9(25.9) T Type of work Quarry, mine T Coal T Gold T Limestone T Others Construction T Construction, civil engineering T Roads T Others

Type of soil

Specific gravity: Rock T Soft T Ordinary T Hard

t/m3 T Gravel T Sand T Clay soil T Coal Kind of operation

T V-shape loading T Cross drive loading T Load and carry

Special notes

Scheduled working hour Replacement/day T1T2T3 Hour/replacement h

Distributor's name

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hour testing
Work order No. Date of inspection

WA1200-6 (CUMMINS) SSDA16V 160E-2

Machine serial No. Engine serial No. Examiner

Service meter reading

Questions asked to operator, walk around inspection Was there any abnormality before inspection started?

Pass Fail

Max. level of coolant temperature

Max. level of torque converter oil temperature

Ambient temperature Max. Min. Height above sea level

C C m

Inspection items Item Conditions Engine: Low idle Engine: High idle 1-1 Engine speed 1 Engine Torque converter stall speed Hydraulic stall Full stall 1-2 Blow-by pressure 1-3 Engine lubricating oil pressure (SAE15W-40) 1-4 Boost pressure 2-1 Torque converter inlet pressure 2-2 Torque converter outlet pressure 3-1 Main relief pressure 3-2 Lubricating oil pressure 3-3 Modulation clutch oil pressure 3-4 1st speed clutch modulating pressure E mode P mode E mode P mode E mode Pmode Emode P mode E mode P mode Unit Standard value for new machine Repair limit 575 to 725 575 to 725 1,800 to 2,000 1,800 to 2,000 1,650 to 2,000 1,700 to 2,000 1,650 to 2,000 1,700 to 2,000 1,500 to 2,000 1,550 to 2,000 3.29 {330} 0.34 {3.5} 0.137 {Min. 1.4} 130 {1,000} Min. 1.22 {Max. 13} 0.88 0.1 { 9 1} 2.7 0.15 {28 1.5} 0.05 to 0.16 {0.5 to 2.7} 2.30 to 2.60 {2.35 to 26.5} 2.45 0.15 {25 1.5} Measurement Pass Fail results

Torque converter stall speed Torque converter stall speed Low idle Torque converter stall speed

625 to 675 625 to 675 1,850 to 1,950 1,850 to 1,950 rpm 1,750 to 1,950 1,800 to 2,000 1,750 to 1,950 1,800 to 2,000 1,600 to 1,950 1,650 to 2,000 kPa Max. 1.25 <mmH20 {Max. 127} 0.34 to 0.48 MPa {3.5 to 4.9} Min. 0.14 <kg/cm2> {Min. 1.43} kPa 150.5 to 180.5 <mmHg> {1,180 to 1,406} Min. 1.22 {Max. 13} 0.88 0.1 {9 1} 2.7 0.15 {28 1.5} 0.05 to 0.16 {0.5 to 2.7} 2.30 to 2.60 {2.35 to 26.5}

Engine: At high idle Torque converter oil pressure: 60 to 80 C Transmission: Neutral

2 T/C

MPa <kg/cm2>

Directional selector switch: Neutral Engine: High idle Torque converter oil temperature: 60 to 80 C

3 Transmission

Directional selector switch: Neutral Gear speed: 1st Directional selec3-5 tor switch: Neu2nd speed clutch modutral lating pressure Gear speed: 2nd Directional selec3-6 tor switch: Neu3rd speed clutch modutral lating pressure Gear speed: 3rd

MPa <kg/cm2>

2.45 0.15 {25 1.5}

2.45 0.15 {25 1.5}

2.45 0.15 {25 1.5}

2.45 0.15 {25 1.5}

2.45 0.15 {25 1.5}

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Item

Conditions

Unit MPa {kg/cm2} Sec.

Standard value for new machine 31.36 (+0.98/-0.29) 320 (+18/-3) Max. 6.5 Max. 5.6

Repair limit 31.36 (+0.98/-1.29) 320 (+10/-13) Max. 7.5 Max. 6.5

Measurement results

Pass

Fail

Engine: At high idle 4 Steering relief pressure Hydraulic oil temperature: 45 to 55C Left lock to Engine: At Hydraulic oil Steering right lock low idle temperature: time (right lock to Engine: At 45 to 55 C high idle left lock) 5-1 Parking brake 5-2 Wheel brake Wear of brake disc Front right Front left Rear right Rear left

4 S/T

Machine must be stationary 0 0 0 0 17.6 (+0.59/0) {180 (6/0)} 20.6 (+1.47/0) {210 (+15/0)} Max. 7.0 Max. 7.0 Max. 7.0 Max. 7.0 17.6 (+0.59/0) {180 (6/0)} 20.6 (+1.47/0) {210 (+15/0)}

mm

5 Brakes

Charge: Cut-in pres5.3 sure Accumulator charge presCharge: sure Cut-out pressure 6-1 Work equipment control valve relief pressure 6-2 PPC Oil Pressure

Engine: At low idle MPa Hydraulic oil <kg/cm2> temperature: 45 to 55 C

Hydraulic oil temperature: 45 to 55 C Engine: At high idle Bucket Tilt Relief Hydraulic oil temperature: 45 to 55 C Engine: At high idle Raise Lower Float Full stroke tilt back Full stroke dump

MPa <kg/cm2>

31.36 (+0.98/-0.29) {320 (+10/-3)} 3.72 to 3.92 {38 to 40} 13.5 0.5 5.3 0.5 5.0 0.5 4.1 0.3

31.36 (+0.98/-1.27) {320 (+10/-13)} 3.52 to 3.92 {36 to 40} 13.5 0.5 5.3 0.5 5.0 0.5 4.1 0.3

6. Hydraulic system

6-3 Lift arm speed (standard and high lift arms) a For work equipment posture, see the stanEngine: At dard value table. 6-4 high idle Bucket speed (standard and high lift arms) a For work equipment posture, see the standard value table.

3.2 0.3

3.2 0.3

7-1 Brake accumulator pressure leakage 7 Accumulator

7-2 PPC accumulator pressure leakage

Brake Front charge: MPa Cut-out 2 >/ <kg/cm pressure Rear 15min Engine stopped Lift arm: Maximum height Lock the work equipment lever and stop the engine. With the engine stopped for one to three minutes, unlock mm the work equipment lock lever and perform a lift arm lower operation. The lift arm should lower to the ground. Bucket hinge pin mm/15mi n

15.7{1,601}

14.74 {1,501} 14.74 {1,501}

15.7{1,601}

8 Hydraulic drift

With lift arm and bucket at a level position

Max. 250 Max. 100

Max. 250 Max. 100

Bucket edge

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 todays check

WA1200-6

30-241

Pm Clinic Pm clinic service

30-242

WA1200-6

SEN0547512-00

40-1

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

4-01

Machine model
WA1200-6

Serial number
60001 and up

40 Troubleshooting

40-1

WA1200-6

40-1

Contents

Contents
40 Troubleshooting General information on troubleshooting.................................................................................. Symptom and troubleshooting numbers .............................................................................. Sequence of events in troubleshooting................................................................................ Check before troubleshooting .............................................................................................. Classification and procedures of troubleshooting ................................................................ Breakage of hydraulic cylinder............................................................................................. Failure codes table............................................................................................................... Symptom and troubleshooting numbers .............................................................................. Information in troubleshooting table..................................................................................... Troubleshooting method for open circuit in wiring harness of pressure sensor system ...... Layout drawing of connector pins ........................................................................................ Connector list and layout ..................................................................................................... T- branch box and T- branch adapter table ......................................................................... Table of fuse locations ......................................................................................................... Troubleshooting by failure code.............................................................................................. Failure code [1500L0] Double Engagement of Transmission Clutches ............................... Failure code [1540N1] T/M overrun ..................................................................................... Failure code [15B0NX] T/M Oil Filter Clogged..................................................................... Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit .................................................. Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect ......................................... Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit .................................................. Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect ......................................... Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit................................................... Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect.......................................... Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit................................................... Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect.......................................... Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit .................................................. Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect ......................................... Failure code [2F00MA] Parking brake circuit failure ............................................................ Failure code [2G42ZG] Accumulator Oil Press. F Low ........................................................ Failure code [2G43ZG] Accumulator Oil Press. R Low........................................................ Failure code [44K0L4] Bucket cylinder position detector SW failure ................................... Failure code [7REAKA] ACC Signal Malfunction ................................................................. Failure code [989P00] Direction protection warning ............................................................ Failure code [989Q00] Work equipment protection ............................................................. Failure code [989R00] Tire slip ............................................................................................ Failure code [989S00] Parking Brake Dragging................................................................... Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF).................................. Failure code [989U00] Stationary steering (Brake: OFF, Load: ON) ................................... Failure code [989V00] Stationary steering (Brake: ON, Load: OFF) ................................... Failure code [989W00] Stationary steering (Brake: ON, Load: ON) .................................... Failure code [AA1ANX] Air Cleaner 1 Clogging................................................................... Failure code [AA1BNX] Air Cleaner 2 Clogging................................................................... Failure code [AA1CNX] Air Cleaner 3 Clogging................................................................... Failure code [AA1DNX] Air Cleaner 4 Clogging................................................................... Failure code [AB00L6] Discharge of alternator R terminal................................................... Failure code [AB00MA] Discharge of alternator R terminal ................................................. Failure code [AB00MB] Discharge of alternator R terminal ................................................. Failure code [B@BCZK] Drop in Engine Coolant Level....................................................... Failure code [b@C5ZK] Low brake fluid level (before engine start) .................................... 40- 8 40- 8 40- 9 40- 10 40- 21 40- 24 40- 27 40- 43 40- 44 40- 46 40- 48 40- 84 40- 104 40- 107 40- 110 40- 110 40- 111 40- 112 40- 114 40- 116 40- 118 40- 120 40- 122 40- 124 40- 126 40- 128 40- 130 40- 132 40- 135 40- 138 40- 140 40- 142 40- 143 40- 144 40- 144 40- 145 40- 146 40- 148 40- 149 40- 150 40- 151 40- 152 40- 154 40- 156 40- 158 40- 160 40- 162 40- 164 40- 166 40- 168

40-2

40-2

WA1200-6

Contents

Failure code [B@C5ZK] Low brake fluid level (while engine is running) ............................. Failure code [B@C6NS] High brake oil temp. ..................................................................... Failure code [b@CENS] High torque converter oil temp. .................................................... Failure code [B@CENS] Very high torque converter oil temp. ............................................ Failure code [B@GAZK] Low battery 1 fluid level................................................................ Failure code [B@GBZK] Low battery 2 fluid level................................................................ Failure code [B@GCZK] Low battery 3 fluid level ............................................................... Failure code [B@HANS] High hydraulic oil temp................................................................. Failure code [B@HAZK] Low hydraulic oil level .................................................................. Failure code [D191KA] Neutral Output Relay Disconnection .............................................. Failure code [D191KB] Neutral Output Relay hot short ....................................................... Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit)............ Failure code [D19MKY] SW pump PNC solenoid Relay hot short....................................... Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure ...................................... Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure ...................................... Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit) ............ Failure code [D5ZHKB] Starting Switch C signal circuit Hot short ....................................... Failure code [D5ZHKZ] Starting Switch C signal circuit failure ............................................ Failure code [D5ZHL6] Ignition C terminal Circuit Failure ................................................... Failure code [DAF5KP] Monitor Panel 5 V source sys Error ............................................... Failure code [DAFRKR] Communication Lost Monitor Panel Controller.............................. Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source ................... Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal ................................... Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source ............. Failure code [DAQRKR] Communication Lost T/M Controller ............................................. Failure code [DAQRMA] Defective Option Selection Data in Transmission ........................ Failure code [DB2RKR] Communication Lost Engine Controller......................................... Failure code [DB90KK] Drop in Work Controller Main Power Source ................................. Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal .................................... Failure code [DB92KK] Solenoid Voltage Failure (Work controller) .................................... Failure code [DB95KX] 5 V source sys Error (Work controller) ........................................... Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller ............ Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller ........ Failure code [DB9RMC] Communication Lost (Work Controller)......................................... Failure code [DBB0KK] VHMS source voltage Error ........................................................... Failure code [DBB0KQ] VHMS Connector Mismatch .......................................................... Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V) ........................ Failure code [DBB5KP] VHMS 5 V source sys Error ........................................................... Failure code [DBB6KP] VHMS 24 V source sys Error ......................................................... Failure code [DBB7KP] VHMS 12 V source sys Error ......................................................... Failure code [DBBQMC] Communication Lost (VHMS CAN0) ............................................ Failure code [DBBRKR] Communication Lost VHMS Controller ......................................... Failure code [DBBRMC] Communication Lost (VHMS CAN1) ............................................ Failure code [DD10KX] Verification Mode SW Failure ........................................................ Failure code [DD1ALD] Remote positioner upper side set sw failure .................................. Failure code [DD1BLD] Remote positioner lower side set sw failure .................................. Failure code [DDA7L4] Throttle Lock Input signal Short Circuit .......................................... Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit ....................... Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit....................... Failure code [DDB6L4] Neutral Signal Malfunction ............................................................. Failure code [DDD7KA] Speed control dial circuit (Low Voltage) ........................................ Failure code [DDD7KB] Speed control dial circuit (High Voltage) ....................................... Failure code [DDDBKA] Traction control dial circuit (Low Voltage) ..................................... Failure code [DDDBKB] Traction control dial circuit (High Voltage) .................................... WA1200-6

40- 169 40- 170 40- 171 40- 172 40- 174 40- 176 40- 178 40- 180 40- 181 40- 182 40- 184 40- 186 40- 188 40- 190 40- 192 40- 194 40- 196 40- 198 40- 200 40- 202 40- 204 40- 206 40- 208 40- 210 40- 212 40- 214 40- 216 40- 218 40- 220 40- 222 40- 224 40- 226 40- 228 40- 230 40- 232 40- 234 40- 236 40- 238 40- 240 40- 242 40- 243 40- 245 40- 246 40- 248 40- 250 40- 252 40- 254 40- 256 40- 258 40- 260 40- 262 40- 264 40- 266 40- 268 40-3

Contents

Failure code [DDE5MA] Emergency steering signal Failure................................................ Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection........................................ Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit........................................... Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)......... Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect .. Failure code [DDT4LD] T/M Cut Off set switch signal short circuit ...................................... Failure code [DDW9LD] Kickdown Switch Short Circuit ...................................................... Failure code [DGE5KX] Ambient air temp Sensor Failure ................................................... Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect ............. Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)........... Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure........................................ Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection................................. Failure code [DGR2KX] Brake oil temp. sensor circuit failure ............................................. Failure code [DGT1KX] T/C oil temp. sensor circuit failure ................................................. Failure code [DH20KX] Torque converter pressure sensor circuit....................................... Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit).............. Failure code [DH21KB] Loader pump oil press sensor hot short......................................... Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit) ............................ Failure code [DHPCKX] Boom bottom press. sensor circuit failure ..................................... Failure code [DHPCKY] Boom bottom press. hot short ....................................................... Failure code [DHPDKX] Boom head press. sensor circuit failure ........................................ Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect ............................ Failure code [DHT2L6] T/M oil filter sensor circuit failure .................................................... Failure code [DHT3KX] Transmission main pressure sensor circuit.................................... Failure code [DHT4KX] Main PPC oil pressure sensor circuit ............................................. Failure code [DHT5KX] Torque converter intake pressure sensor circuit............................ Failure code [DHT8KX] Steering Oil Press. Sensor Failure................................................. Failure code [DHTAKX] Transmission lubrication pressure sensor circuit........................... Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect................... Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit .................. Failure code [DHU2KA] F Brake Oil press Sensor Disconnect............................................ Failure code [DHU2KB] F Brake Oil press Sensor Hot short............................................... Failure code [DHU2KX] F Brake Oil press Sensor Failure .................................................. Failure code [DHU3KA] R Brake Oil press Sensor Disconnect ........................................... Failure code [DHU3KB] R Brake Oil press Sensor Hot short .............................................. Failure code [DHU3KX] R Brake Oil press Sensor Failure .................................................. Failure code [DJF1KA] Fuel level sensor circuit Disconnection........................................... Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit).................. Failure code [DK30KY] Steering lever angle sensor circuit hot short .................................. Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit) ......... Failure code [DK59KY] Boom lever potentiometer (main) hot short .................................... Failure code [DK59L8] Boom lever potentiometer (main & sub) failure............................... Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)........... Failure code [DK5AKY] Boom lever potentiometer (sub) hot short...................................... Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit) ....... Failure code [DK5BKY] Bucket lever potentiometer (main) hot short .................................. Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure............................. Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)......... Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short.................................... Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit) .............................. Failure code [DKA0KX] Boom angle sensor circuit failure................................................... Failure code [DKA0KY] Boom angle sensor circuit hot short............................................... Failure code [DKA0L0] Boom angle sensor failure .............................................................. 40-4

40- 270 40- 272 40- 274 40- 276 40- 278 40- 280 40- 282 40- 284 40- 286 40- 288 40- 290 40- 292 40- 294 40- 296 40- 298 40- 300 40- 302 40- 304 40- 306 40- 308 40- 310 40- 312 40- 314 40- 316 40- 318 40- 320 40- 322 40- 324 40- 326 40- 328 40- 330 40- 332 40- 334 40- 336 40- 338 40- 340 40- 341 40- 343 40- 344 40- 345 40- 346 40- 348 40- 349 40- 352 40- 354 40- 356 40- 358 40- 359 40- 362 40- 363 40- 364 40- 366 40- 368 40- 370 WA1200-6

Contents

Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)............................. Failure code [DKD0KY] Frame angle sensor circuit hot short ............................................. Failure code [DKD0KZ] Frame and steering angle sensor failure ....................................... Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect ............................................ Failure code [DKH0KB] Angle sensor circuit (FR) Hot short ............................................... Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect ............................................ Failure code [DKH1KB] Angle sensor circuit (LR) Hot short................................................ Failure code [DLE2KA] Engine Speed Sensor Disconnection............................................. Failure code [DLE2LC] Engine Speed Sensor Short Circuit................................................ Failure code [DLF6LC] Tire speed sensor circuit ................................................................ Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect....................................... Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit ..................................... Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit ................................. Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection .............................. Failure code [DT20KB] Transmission cut off indicator Output short circuit ......................... Failure code [DT21KB] Speed Control indicator Output short circuit................................... Failure code [DUM8KB] VHMS Operation lamp Short Circuit ............................................. Failure code [DV00KY] Buzzer circuit hotshort (for usually)................................................ Failure code [DV01KY] Buzzer circuit hotshort (for special)................................................ Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection......................... Failure code [DW23KB] T/M E-POCV (F bypass) Solenoid Short Circuit ........................... Failure code [DW23KY] T/M E-POCV (F bypass) Solenoid circuit Hot short ...................... Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection ........................ Failure code [DW24KB] T/M E-POCV (R bypass) Solenoid Short Circuit ........................... Failure code [DW24KY] T/M E-POCV (R bypass) Solenoid circuit Hot short...................... Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection ...................... Failure code [DW25KB] T/M E-POCV (1st bypass) Solenoid Short Circuit ......................... Failure code [DW25KY] T/M E-POCV (1st bypass) Solenoid circuit Hot short.................... Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection ................................. Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault .................................. Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short ....................................... Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection .............................. Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit ............................ Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short ................................ Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection................................... Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault...................................... Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short........................................... Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection ................................. Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit ................................. Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short...................................... Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection ................................. Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault .................................. Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short ....................................... Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection ........................ Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault ................................. Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short ...................................... Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection ...................................... Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault ........................................... Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short .............................................. Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection ................................. Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit..................................... Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short ......................................... Failure code [DWJ2KA] T/M E-POCV (R drain) Solenoid Disconnection ............................ Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit............................... WA1200-6

40- 372 40- 373 40- 374 40- 375 40- 376 40- 378 40- 380 40- 382 40- 384 40- 386 40- 388 40- 390 40- 392 40- 394 40- 396 40- 397 40- 398 40- 400 40- 402 40- 404 40- 405 40- 406 40- 407 40- 408 40- 409 40- 410 40- 411 40- 412 40- 413 40- 414 40- 415 40- 416 40- 417 40- 418 40- 419 40- 420 40- 421 40- 422 40- 423 40- 424 40- 425 40- 426 40- 427 40- 428 40- 429 40- 430 40- 431 40- 432 40- 433 40- 434 40- 435 40- 436 40- 437 40- 438 40-5

Contents

Failure code [DWJ2KY] T/M E-POCV (R drain) Solenoid circuit Hot short.......................... Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection .................. Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit ...................... Failure code [DWM1KY] Work equipment neutral lock solenoid hot short .......................... Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection.................... Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit ....................... Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short............................ Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection..................... Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit ........................ Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short............................. Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection ...................... Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit............................ Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short ................................ Failure code [DWNAKA] NC solenoid disconnection........................................................... Failure code [DWNAKB] NC solenoid short circuit .............................................................. Failure code [DWNAKY] NC solenoid hot short................................................................... Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit) ............... Failure code [DXA1KY] Loader pump solenoid Relay hot short .......................................... Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)............... Failure code [DXF0KA] AJSS EPC solenoid disconnection ................................................ Failure code [DXF0KB] AJSS EPC solenoid short circuit .................................................... Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection ................................... Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit...................................... Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short................................. Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection.................................. Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit..................................... Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short ............................... Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection................................... Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit ..................................... Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short ................................ Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection ..................................... Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit ........................................ Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short................................... Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection...................................... Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit ........................................ Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short ................................... Failure code [DXHPKA] T/M E-POCV (MOD/C) Solenoid Disconnection ........................... Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit .............................. Failure code [DXHPKY] T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V.................. Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction ............................... Troubleshooting of electrical system (E-mode),...................................................................... E-1 Remote positioner "RAISE" or "LOWER" LED does not light up................................... E-2 Open circuit or ground fault in check lamp system........................................................ E-3 Machine monitor does not operate................................................................................ E-4 Turn signal lamp does not light up ................................................................................ E-5 Defective parking lamp.................................................................................................. E-6 Defective front working lamp ......................................................................................... E-7 Defective rear working lamp.......................................................................................... E-8 Headlamp does not light up........................................................................................... E-9 Service meter does not work, or service meter works while engine is stopped. ........... E-10 Monitor panel controller does not sound buzzer ......................................................... E-11 Defective auto-greasing system .................................................................................. Troubleshooting of hydraulic and mechanical system (H-mode) ............................................

40- 439 40- 440 40- 441 40- 442 40- 443 40- 444 40- 445 40- 446 40- 447 40- 448 40- 449 40- 450 40- 451 40- 452 40- 453 40- 454 40- 455 40- 457 40- 459 40- 461 40- 463 40- 465 40- 467 40- 469 40- 471 40- 473 40- 475 40- 477 40- 479 40- 481 40- 483 40- 485 40- 487 40- 489 40- 491 40- 493 40- 494 40- 495 40- 496 40- 497 40- 499 40- 499 40- 500 40- 501 40- 502 40- 504 40- 506 40- 508 40- 510 40- 512 40- 514 40- 516 40- 518

40-6

WA1200-6

Contents

Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor) ....................................................................................................................... Work equipment hydraulic system, general ......................................................................... Work equipment oil pressure group..................................................................................... Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)................................................................................................................................ Checking steering related standard values.......................................................................... Steering oil pressure system, general ................................................................................. Steering oil pressure group.................................................................................................. Brake oil pressure system, general ..................................................................................... Brake oil pressure group...................................................................................................... Information contained in troubleshooting table (H mode) .................................................... H-1 Torque converter oil temperature rises too high (overheats) ........................................ H-2 Turning or response of steering is poor ........................................................................ H-3 AJSS lever is hard to operate ....................................................................................... H-4 Steering shakes or jolts................................................................................................. H-5 Wheel brake does not work at all or is weak................................................................. H-6 Lift arm speed is low or lift arm rising force is insufficient ............................................. H-7 Shock is large when lift arm stops ................................................................................ H-8 Hydraulic oil temperature rises too high (overheating) .................................................

40- 518 40- 528 40- 530 40- 595 40- 608 40- 609 40- 610 40- 650 40- 651 40- 701 40- 702 40- 705 40- 708 40- 710 40- 712 40- 714 40- 717 40- 718

WA1200-6

40-7

General information on troubleshooting Symptom and troubleshooting numbers

General information on troubleshooting

Symptom and troubleshooting numbers
k k k k k k

40-8

40-8

(Rev. 2010/03) Stop the machine on a level place, and check that the lock pin, blocks, and parking brake are securely fitted. 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. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the cable from the negative () terminal of the battery first. When removing the plug or cap from a component which is under pressure of oil, water, or air, always 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 prevent reoccurrence of the failure. When performing troubleshooting, an important point is of course to understand 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 symptoms. 1. When performing troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after any failure occurs: q Parts that have no connection with the failure or other unnecessary parts will be disassembled. q It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation and to perform troubleshooting in accordance with the fixed procedure. 2. Points to ask the user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before the failure? 4) Under what conditions did the failure occur? 5) Had any repairs been performed before the failure? When were these repairs performed? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check the machine for other symptoms of failure. 40-8 2) Perform checks on items listed in "Checks before starting". 3) Perform checks on other checking items. 4) Check other maintenance matters which can be checked externally and are considered to be necessary. 4. Checking failure symptom Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the method of operation, etc. a When operating the machine to reproduce the failure symptom, do not perform any inspection or measurement that may make the problem worse. 5. Troubleshooting Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of the failure, then use the troubleshooting flowchart to locate the failure exactly. a The basic procedure for troubleshooting is as follows. 1] Start from the simple points. 2] Start from the most likely points. 3] Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the immediate failure is removed, the same failure may occur again, unless the root cause of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove the root cause.

WA1200-6

General information on troubleshooting Sequence of events in troubleshooting

Sequence of events in troubleshooting

40-9
(Rev.2007.12)

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40-9

General information on troubleshooting Check before troubleshooting

Check before troubleshooting

No. 1 Check of unusual noise and smell 2 Check of engine for dirt 3 Check of engine for water leakage a: Engine, lubricating oil and coolant 4 Check of engine for oil leakage 5 Check of fuel line for leakage 6 Check of radiator for clogging 7 Check of fuel level and type 8 Check of foreign material in fuel 9 Check of fuel filter 10 Check of engine oil level (in oil pan) and type 11 Check of coolant level (in sub tank) Item Criterion Between H and L Between H and L No clogging indication on monitor Between H and L Between H and L Between H and L Between H and L Remedy Repair Remove Repair Repair Repair Remove Refill with fuel Clean and drain Replace Refill with oil Refill with coolant

40-10

12 Check of air cleaner for clogging

Clean or replace

1 Check for unusual noise and smell 2 Check for oil leakage b: Hydraulic and mechanical equipment 3 Check of hydraulic oil 4 Check of hydraulic oil strainer 5 Check of hydraulic oil filter 6 Check of power train case oil level 7 Check of power train pump strainer 8 Check of transmission oil filter and torque converter oil filter 9 Check of damper case oil level 10 Check of final drive case oil level 11 Bleed air

Repair Repair Refill with oil Clean and drain Replace Refill with oil Clean and drain Clean and drain Refill with oil Refill with oil Bleed air

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General information on troubleshooting Check before troubleshooting

No.

Item

Criterion during illuminance increase adjustment Between H and L After several minutes operation: 27.5 - 29.5 V

Remedy Retighten or replace Retighten or replace Retighten or replace

1 Check of battery terminals for looseness and corrosion 2 Check of alternator terminals for looseness and corrosion 3 Check of starting motor terminals for looseness and corrosion

4 Check of battery voltage (with engine stopped)

Charge or replace

5 Check of battery electrolyte level 6 Check of wiring harness for discoloration, burnt areas and cover peeling c: Electrical equipment 7 Check of wiring harness for coming off from clamp and sagging 8 Check of grounding 9 Check for loose connector and damaged lock 10 Check of connector pin for corrosion, bending and deformation 11 Check for water and foreign material in connector 12 Check of wiring harness for open or short circuit 13 Check of fuse for blowout and corrosion 14 Check of circuit breaker

Add or replace Repair or replace Repair Repair Repair or replace Repair or replace Dry, clean or replace Repair or replace Replace Push in reset button

15 Check of alternator voltage (when engine speed is medium or higher)

Replace

16 e: Interior parts d: Exterior parts

Check of battery relay operation sound (when the starting switch is turned to ON or OFF position)

Replace Repair Repair Clean or repair Clean or replace Repair

1 Check of undercarriage 2 Check of handrails and steps 3 Check of mirrors 1 Check of gauges and monitors 2 Check of seat belt

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General information on troubleshooting Check before troubleshooting

Testing procedure before troubleshooting Walk-around check

40-12 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 Check for unusual noise and smell. Some causes of unusual noise and smell can damage the machine if they are left as they are. Therefore, stop the machine immediately when you find any abnormality. a2. Check around engine and dirt removal Check for and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.) on hot engine parts such as the engine muffler, turbocharger, etc. a3. Check of engine for water leakage a4. Check of engine for oil leakage Check for any oil leaks from the engine and any water leaks from the cooling system, and then repair any failures. a5. Check for leakage from fuel line Check for any fuel leaks and damaged hoses and tubes, and then repair any failures. a6. Check of radiator and dirt removal Check for and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator. For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with the air conditioner)". 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. b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage Check and repair any oil leaks. c1. Check around battery and dirt removal Check for and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the battery. d1. Check of undercarriage for defect, wear, loose bolts and oil leakage from axle and final drive Repair any failures. d2. Check of handrails and steps for defect and loose bolts Repair any failures and retighten any loose bolts. d3. Check and cleaning of rear view mirrors Check for and repair any defective and broken rear view mirrors. Clean the mirror surfaces and adjust their angles so that the operator can see the area behind machine at the operator's seat. e1. Check of gauges and monitors for defect Check the gauges and monitors inside the operator's cab. If any of them is defective, replace it. Clean up the surfaces. e2. Check of seat belt and mounting hardware Check the hooks, locks and hook fittings for damage, and then repair any failures.

40-12

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General information on troubleshooting Check before troubleshooting

Test according to testing procedure a. Engine, lubricating oil and coolant

40-13 40-13

a7. Check of fuel level and type k Fuel is flammable and dangerous.Do not bring any open flame near fuel. k When adding fuel, take care not to let it overflow. k Wipe off completely any spilt fuel.If fuel has spilled over soil or sand, remove that soil or 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 position.

a8. Check for foreign material in fuel 1. Open three drain cocks (1) on the right side of the fuel tank. 2. Place a container under the drain hose to receive the drained fuel. 3. Turn the drain valve to the "OPEN" position to discharge the sediment and water in the bottom together with the fuel. 4. When only the clean fuel flows out, close the drain valve.

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 filter.

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General information on troubleshooting Check before troubleshooting

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. High pressure is generated inside the engine fuel piping system when the engine is running.Wait for at least 30 seconds after stopping the engine until the internal pressure decreases, and then replace the filter.

a9. Check of fuel filter 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. k High pressure is generated inside the engine fuel piping system when the engine is running.Wait for at least 30 seconds after stopping 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 special filter that has highly efficient filtering performance.When replacing, always use a Komatsu genuine cartridge.

a When testing and servicing the fuel system, be extremely careful that no foreign material enters. If any dirt sticks, remove it completely by using fuel. q Prepare a container to receive the fuel. q Prepare the filter wrench.

Do not bring any open flame near the filter. a Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering performance.When replacing, always use a Komatsu genuine cartridge.

a When testing and servicing the fuel system, be extremely careful that no foreign material enters. If any dirt sticks, remove it completely by using fuel. 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.

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General information on troubleshooting Check before troubleshooting

4. Place the fuel container under filter cartridge (2). 5. By using the filter wrench, rotate filter cartridge (2) to the left to remove.

a10. Check of engine oil level (in oil pan) and type 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.

7. Install the filter cartridge. a When installing the filter cartridge, tighten it by 3/4 turns after its O-ring has been securely placed on the sealing surface of the filter head. 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".

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 filler port (2). 6. If the oil level is above H 1) Remove the cover from the machine bottom and place a drain oil container directly below it. 2) Loosen drain plug (1) to drain excess oil.

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.

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General information on troubleshooting Check before troubleshooting

a11. Check of coolant level 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 remove it with care.I 1. Open the cover on the rear left side of the machine, and check that the coolant level is between the FULL and LOW marks on the gauge.
k

3. After adding the coolant, tighten the cap securely. a12. Check of air cleaner for clogging k When using compressed air for cleaning, put on personal protective items such as protective 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 footing, 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 warning (A) is displayed on the multi monitor.

2. If the reservoir tank is empty, there may be 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 realized 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.

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General information on troubleshooting Check before troubleshooting

Cleaning of element a Do not leave or store the element in direct sunlight before or after cleaning it. a Replace the outer element if it is cleaned six times repeatedly or used throughout a year.Replace 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).

a After cleaning, light up the inside of the element to check it. If the element has a small hole or a thin part, replace it.

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.

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General information on troubleshooting Check before troubleshooting

b. Hydraulic and mechanical equipment

40-18

b3. Check of hydraulic oil level 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. 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. 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 circuit 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.

4. 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 with dipstick (1) when adding oil.

40-18

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General information on troubleshooting Check before troubleshooting

b4. Check of hydraulic oil strainer 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. 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. Stop the engine and remove the oil filler cap of the hydraulic tank to release the internal pressure. 2. Remove the mounting bolts to remove cover (1).

4. Loosen nut (5) and remove strainer (4). 5. Remove all dirt from strainer (4), then wash in clean diesel oil or flushing oil. If strainer (4) is damaged, replace it with a new one. 6. Install strainer (4) to holder (3) and tighten nut (5). 3 Nut: 5974 Nm {6.07.5 kgm} 7. Install holder (3). Replace O-ring (6) of the holder with a new one.

3. Loosen bolt (2) and remove holder (3) together with strainer (4) from the hydraulic tank.

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40-19

General information on troubleshooting Check before troubleshooting

b5. Check of hydraulic oil filter 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. 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.
k

3. Prepare a container to receive the drained oil. 4. Remove drain plug (3) at the tank bottom and loosen drain valve (2) to drain the oil. a When loosening drain plug (3), take care that the oil does not splash over you.

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). a If air bleeding is insufficient, the piston pumps and cylinders may be damaged. Bleed air completely. 12. After bleeding air, tighten plug (1). 3 Plug: 9.812.8 Nm {1.01.3 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.

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General information on troubleshooting Classification and procedures of troubleshooting

Classification and procedures of troubleshooting

Classification of troubleshooting
Mode Display of code Troubleshooting by failure code E-mode H-mode Troubleshooting of electrical system Troubleshooting of hydraulic and mechanical system Content

40-21
40-21

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 troubleshooting 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.

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40-21

General information on troubleshooting Classification and procedures of troubleshooting

Check of failure code 1. Procedure for switching to service mode and screen display To use the service mode, perform the following procedure to change screen displays. a With the standard screen displayed, press the [F3] switch to go to the date setting display screen. 1) Date setting display screen The service mode is accessed by way of the this screen.

40-2 2. Abnormality record display function The multi monitor logs the failures which occurred in the past or which are occurring at present. a After entering service ID, press the [F6] switch to display the service menu selecting screen.

q q q

Press and release the [F2] and [F5] switches at the same time to access the service ID input screen. When the [F1] switch is pressed, the screen returns to the standard screen.

Select the abnormality record by pressing [F3] or [F4] switch. Press the [F6] switch to move to the abnormality record screen. Press the [F1] switch to return to the date setting screen.

1) Abnormality record display screen

2) Service ID input screen

Press the [F3] or [F4] switch to move to the "numeric value" to be entered. q When the [F5] switch is pressed, the selected numeric value is entered. 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.
q

q q

Scroll the item by pressing [F3] or [F4] switch. Skip over three items to display every fourth one by pressing [F2] or [F5]. Press the [F1] switch to return to the service menu selecting screen.

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General information on troubleshooting Classification and procedures of troubleshooting

2) Information displayed on "Abnormality Record" screen The abnormality record display screen shows failure information on the screen as follows. (a): Failures occurring in reverse chronological 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". 3. Memory clear function The memory clear function erases data stored in the KOMTRAX Plus, including the abnormality record, maintenance, trend, load map, and snap shot. a After entering ID, press the [F6] switch to display the service menu selecting screen.

1) Abnormality record memory clear

q q

Select memory clear item abnormality record by pressing [F3] or [F4] switch. Press the [F6] switch to move to the abnormality record erase confirm screen.

2) Abnormality record memory clear confirmation screen This screen prompts you to determine whether to erase the abnormality record or not. Confirm erasure by pressing the [F2] or [F5] switch.

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 [F1] switch to return to the date setting screen. a After entering memory clear ID, press the [F6] switch to move to the memory clear screen.
q

Press the [F5] switch to clear the abnormality record, and the screen returns to the memory clear screen.

WA1200-6

40-23

General information on troubleshooting 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.

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General information on troubleshooting Breakage of hydraulic cylinder

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 cylinder
1. Piston seal 2. Backup ring
q

shown

on

the

hydraulic

3. Back ring 4. Wear ring

<Reference> Burns and breakage resulting from diesel-like ignition will occur locally (in a limited area). q Closely examine parts for burns and damage.

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40-25

General information on troubleshooting Breakage of hydraulic cylinder

q q q

Burns are found.It may be difficult to find burns on originally black-colored parts (part g). Damage will occur locally (part h). 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.

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General information on troubleshooting Failure codes table

Failure codes table

Failure code Failure (Displayed on screen) Component in charge Transmission Transmission Monitor Panel Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Monitor Panel Monitor Panel Monitor Panel Boom Bucket & AJSS KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus Monitor Panel Monitor Panel Monitor Panel Monitor Panel Monitor Panel Action code E03 E02 E01 E03 E01 E03 E01 E03 E01 E03 E01 E03 E01 E03 E03 E03 E01 E01 E01 E01 E01 E01 E01 Category of record Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Reference document page 40-110 40-111 40-112 40-114 40-116 40-118 40-120 40-122 40-124 40-126 40-128 40-130 40-132 40-135 40-138 40-140 40-142 40-143 40-144 40-144 40-145 40-146 40-148 40-149 40-150 40-151 40-152 40-154 40-156 40-158 40-160

40-27

1500L0 Double Engagement of Transmission Clutches 1540N1 T/M overrun 15B0NX T/M Oil Filter Clogged 15SAL1 ECMV (F) Fill Switch Short Circuit 15SALH ECMV (F) Fill Switch circuit Disconnect 15SBL1 ECMV (R) Fill Switch Short Circuit 15SBLH ECMV (R) Fill Switch circuit Disconnect 15SEL1 ECMV (1) Fill Switch Short Circuit 15SELH ECMV (1) Fill Switch circuit Disconnect 15SFL1 ECMV (2) Fill Switch Short Circuit 15SFLH ECMV (2) Fill Switch circuit Disconnect 15SGL1 ECMV (3) Fill Switch Short Circuit 15SGLH ECMV (3) Fill Switch circuit Disconnect 2F00MA Parking brake circuit failure 2G42ZG Accumulator Oil Press. F Low 2G43ZG Accumulator Oil Press. R Low 44K0L4 Bucket cylinder position detector SW failure 7REAKA ACC Signal Malfunction 989P00 Direction protection warning 989Q00 Work equipment protection 989R00 Tire slip 989S00 Parking Brake Dragging 989T00 Stationary steering (Brake: OFF, Load: OFF) 989U00 Stationary steering (Brake: OFF, Load: ON) 989V00 Stationary steering (Brake: ON, Load: OFF) 989W00 Stationary steering (Brake: ON, Load: ON) AA1ANX Air Cleaner 1 Clogging AA1BNX Air Cleaner 2 Clogging AA1CNX Air Cleaner 3 Clogging AA1DNX Air Cleaner 4 Clogging AB00L6 Discharge of alternator R terminal

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code AB00MA AB00MB B@BCZK b@C5ZK B@C5ZK B@C6NS b@CENS B@CENS B@GAZK B@GBZK B@GCZK B@HANS B@HAZK CA115 CA135 CA141 CA144 CA145 CA146 CA151 CA153 CA154 CA155 CA156 CA157 CA158 CA159 CA161 CA162 CA163 CA164 CA165 CA187 CA212 CA213 Failure (Displayed on screen) Discharge of alternator R terminal Discharge of alternator R terminal Drop in Engine Coolant Level Low brake fluid level(before engine start) Low brake fluid level(while engine is running) High brake oil temp. High torque converter oil temp. Very high torque converter oil temp. Low battery 1 fluid level Low battery 2 fluid level Low battery 3 fluid level High hydraulic oil temp. Low hydraulic oil level Component in charge Action code E03 E03 E01 E01 E03 E02 E02 E02 E01 E01 E01 E02 E01 E03 E01 E01 E01 E01 E02 E02 E01 E01 E02 E01 E01 E02 E01 E01 E02 E01 E01 E02 E01 E01 E01 Reference Category of record document page Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system 40-162 40-164 40-166 40-168 40-169 40-170 40-171 40-172 40-174 40-176 40-178 40-180 40-181 A A A A A A A A A A A A A A A A A A A A A A

Monitor Panel KOMTRAX Plus Monitor Panel KOMTRAX Plus KOMTRAX Plus Monitor Panel Monitor Panel Monitor Panel KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus Monitor Panel Monitor Panel Engine Engine Speed Signal Lost (Cummins) Engine Oil pressure sensor circuit failed High (Cummins) Engine Oil pressure sensor circuit failed Low (Cummins) Engine Coolant temp. sensor circuit failed High (Cummins) Engine Coolant temp. sensor circuit failed Low (Cummins) Engine High coolant temp. (Cummins) Engine High coolant temp. Most severe level (Cummins) Intake temp. sensor circuit failed High - Left Engine Bank Front (Cummins) Intake temp. sensor circuit failed Low - Left Engine Bank Front (Cummins) High intake temp. - Left Bank Front Most severe Engine level (Cummins) Intake temp. sensor circuit failed High - Right Engine Bank Front (Cummins) Intake temp. sensor circuit failed Low - Right Engine Bank Front (Cummins) 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 Sensor supply 2 circuit failed Low (Cummins) Engine Engine oil temp. sensor circuit failed High (Cummins) Engine Engine oil temp. sensor circuit failed Low (Cummins)

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code CA214 CA221 CA222 CA227 CA228 CA231 CA232 CA234 CA238 CA261 CA263 CA265 CA266 CA271 CA272 CA285 CA286 CA319 CA323 CA331 CA342 CA343 CA349 CA351 CA352 CA386 CA415 CA418 CA421 CA431 Failure (Displayed on screen) High Engine Oil Temp. Most severe level Ambient Air Pressure sensor circuit failed High Ambient Air Pressure sensor circuit failed Low Sensor supply 2 circuit failed High Low coolant pressure. Most severe level Coolant pressure sensor circuit failed High Coolant pressure sensor circuit failed Low Engine overspeed Sensor supply 3 circuit failed Low High fuel temp. Fuel temp. sensor circuit failed High Fuel temp. sensor circuit failed Low High fuel temp. Most severe level Fuel pump pressurizing circuit failed Low Fuel pump pressurizing circuit failed High Communication Lost (EMC) PGN Timeout Error Communication Lost (EMC) Configuration Error Real Time Clock Power Error Injector Solenoid Driver Cyl 5 circuit failed Low Injector Solenoid Driver Cyl 2 circuit failed Low Calibration Incompatibility Error ECM hardware failure AXG speed High error Injector Power Supply failed Low Sensor supply 1 circuit failed Low Sensor supply 1 circuit failed High Low oil pressure. Most severe level Water in fuel least severe level High Engine Oil Temp. Idle Validation Invalid Component in charge Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Action code E02 E01 E01 E01 E03 E01 E01 E03 E01 E02 E01 E01 E03 E01 E01 E03 E03 E01 E01 E03 E01 E01 E01 E01 E01 E03 E02 E01 Reference Category of record document page Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code CA441 CA442 CA449 CA451 CA452 CA488 CA489 CA546 CA547 CA556 CA559 CA611 CA689 CA731 CA783 Failure (Displayed on screen) Low Battery Voltage High Battery Voltage High common rail pressure Most severe level Fuel rail pressure circuit failed High Fuel rail pressure circuit failed Low High intake temp. - Left Bank Front AXG speed Low error Fuel pressure sensor circuit failed High Fuel pressure sensor circuit failed Low High Crankcase Pressure Most severe level High fuel rail pressure Engine Hot Shutdown Engine crankshaft speed failed Engine speed misalignment Camshaft and Crankshaft Rapid rise intake manifold temp. Left Bank Front Component in charge Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Action code E01 E01 E03 E01 E01 E02 E01 E01 E01 E03 E01 E01 E01 E02 E03 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 Reference Category of record document page Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Mechanical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

CA1117 Power Lost with Ignition On CA1257 Module ID Input State Error CA1358 Accelerator pedal sensor circuit failed High CA1359 Accelerator pedal sensor circuit failed Low CA1363 Low intake manifold pressure Left bank Front CA1373 Ether solenoid circuit failed CA1376 Engine camshaft speed failed CA1383 Intake pressure sensor circuit failed High - Left Bank Front Intake pressure sensor circuit failed Low - Left CA1384 Bank Front CA1542 Engine oil level sensor circuit failed High CA1543 Engine oil level sensor circuit failed Low CA1544 Low engine oil level CA1549 Injector Solenoid Driver Cyl 8 circuit failed Low CA1551 Injector Solenoid Driver Cyl 10 circuit failed Low CA1552 Injector Solenoid Driver Cyl 11 circuit failed Low

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code Failure (Displayed on screen) Component in charge Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Action code E01 E01 E01 E01 E01 E01 E01 E01 E02 E02 E02 E02 E02 E02 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 Reference Category of record document page Electrical system Mechanical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

CA1557 Injector Solenoid Driver Cyl 16 circuit failed Low CA1638 Low intake manifold pressure Right bank Front CA1843 Crankcase pressure sensor circuit failed High CA1844 Crankcase pressure sensor circuit failed Low CA1845 Water in fuel sensor circuit failed High CA1846 Water in fuel sensor circuit failed Low CA1852 Water in fuel CA1889 Communication Lost (EMC) Remote Accelerator Pedal

CA1911 High common rail pressure CA1984 High intake temp. - Right Bank Front CA1985 High intake temp. - Left Bank Rear CA1986 High intake temp. - Right Bank Rear CA2157 Rapid rise intake manifold temp. Right Bank Front Rapid rise intake manifold temp. Right Bank CA2158 Front Rapid rise intake manifold temp. Right Bank CA2159 Rear CA2185 Sensor supply 4 circuit failed High CA2186 Sensor supply 4 circuit failed Low CA2215 Low fuel pump delivery pressure CA2261 High fuel pump delivery pressure Least severe Level Low fuel pump delivery pressure Least severe CA2262 Level CA2265 Lift Pump Supply Circuit failed High CA2266 Lift Pump Supply Circuit failed Low CA2311 Fuel injection control valve circuit failed CA2474 Turbocharger speed failed CA2697 Accelerator pedal Idle validation circuit failed CA2727 Communication Lost (EMC) between Parent and Child

CA2734 Ether bottle empty CA2963 High engine coolant temp. Least severe level CA2964 CB115 High Intake Manifold Temp. Left Bank Front Least severe level Engine Speed Signal Lost

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code CB187 CB227 CB238 CB325 CB332 CB342 CB343 CB351 CB352 CB386 CB441 CB442 CB621 CB622 CB623 CB624 CB625 CB626 CB627 CB628 CB631 CB632 CB633 CB634 CB635 CB636 CB637 CB638 CB689 CB721 Failure (Displayed on screen) Sensor supply 2 circuit failed Low Sensor supply 2 circuit failed High Sensor supply 3 circuit failed Low Injector Solenoid Driver Cyl 6 circuit failed Low Injector Solenoid Driver Cyl 4 circuit failed Low Calibration Incompatibility Error ECM hardware failure Injector Power Supply failed Low Sensor supply 1 circuit failed Low Sensor supply 1 circuit failed High Low Battery Voltage High Battery Voltage Low Exhaust Temp. Left Bank #1 Low Exhaust Temp. Left Bank #2 Low Exhaust Temp. Left Bank #3 Low Exhaust Temp. Left Bank #4 Low Exhaust Temp. Left Bank #5 Low Exhaust Temp. Left Bank #6 Low Exhaust Temp. Left Bank #7 Low Exhaust Temp. Left Bank #8 Low Exhaust Temp. Right Bank #1 Low Exhaust Temp. Right Bank #2 Low Exhaust Temp. Right Bank #3 Low Exhaust Temp. Right Bank #4 Low Exhaust Temp. Right Bank #5 Low Exhaust Temp. Right Bank #6 Low Exhaust Temp. Right Bank #7 Low Exhaust Temp. Right Bank #8 Engine crankshaft speed failed Exhaust Temp. sensor circuit failed low Right Bank #1 Component in charge Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Action code E01 E01 E01 E01 E01 E03 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code CB722 CB723 CB724 CB725 CB726 CB727 CB728 CB731 Failure (Displayed on screen) Exhaust Temp. sensor circuit failed low Right Bank #2 Exhaust Temp. sensor circuit failed low Right Bank #3 Exhaust Temp. sensor circuit failed low Right Bank #4 Exhaust Temp. sensor circuit failed low Right Bank #5 Exhaust Temp. sensor circuit failed low Right Bank #6 Exhaust Temp. sensor circuit failed low Right Bank #7 Exhaust Temp. sensor circuit failed low Right Bank #8 Engine speed misalignment Camshaft and Crankshaft Component in charge Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Action code E01 E03 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

CB1117 Power Lost with Ignition On CB1257 Module ID Input State Error CB1362 Engine oil filter clogging CB1367 Pre oil filter pressure sensor circuit failed High CB1368 Pre oil filter pressure sensor circuit failed Low CB1376 Engine camshaft speed failed CB1377 Post oil filter pressure sensor circuit failed High CB1378 Post oil filter pressure sensor circuit failed Low CB1385 CB1386 CB1529 CB1531 CB1532 CB1533 CB1534 CB1535 CB1536 Intake pressure sensor circuit failed High - Right Bank Front Intake pressure sensor circuit failed Low - Right Bank Front Exhaust temp. sensor circuit failed High - Right Bank #1 Exhaust temp. sensor circuit failed High - Right Bank #3 Exhaust temp. sensor circuit failed High - Right Bank #4 Exhaust temp. sensor circuit failed High - Right Bank #5 Exhaust temp. sensor circuit failed High - Right Bank #6 Exhaust temp. sensor circuit failed High - Right Bank #7 Exhaust temp. sensor circuit failed High - Right Bank #8

CB1548 Injector Solenoid Driver Cyl 7 circuit failed Low CB1553 Injector Solenoid Driver Cyl 12 circuit failed Low CB1555 Injector Solenoid Driver Cyl 14 circuit failed Low CB1619 Exhaust temp. sensor circuit failed High - Right Bank #2

CB1622 Injector Solenoid Driver Cyl 9 circuit failed Low

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code Failure (Displayed on screen) Component in charge Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Engine (Cummins) Action code E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E01 E01 E01 E01 E01 E03 E01 E01 E01 E01 E01 Reference Category of record document page Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Electrical system Electrical system Electrical system Electrical system A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

CB2121 High exhaust temp. Left Bank #1 CB2122 High exhaust temp. Left Bank #2 CB2123 High exhaust temp. Left Bank #3 CB2124 High exhaust temp. Left Bank #4 CB2125 High exhaust temp. Left Bank #5 CB2126 High exhaust temp. Left Bank #6 CB2127 High exhaust temp. Left Bank #7 CB2128 High exhaust temp. Left Bank #8 CB2131 High exhaust temp. Right Bank #1 CB2132 High exhaust temp. Right Bank #2 CB2133 High exhaust temp. Right Bank #3 CB2134 High exhaust temp. Right Bank #4 CB2135 High exhaust temp. Right Bank #5 CB2136 High exhaust temp. Right Bank #6 CB2137 High exhaust temp. Right Bank #7 CB2138 High exhaust temp. Right Bank #8 CB2185 Sensor supply 4 circuit failed High CB2186 Sensor supply 4 circuit failed Low CC115 CC187 CC227 CC238 CC322 CC324 CC342 CC343 CC351 CC352 CC386 CC441 Engine Speed Signal Lost Sensor supply 2 circuit failed Low Sensor supply 2 circuit failed High Sensor supply 3 circuit failed Low Injector Solenoid Driver Cyl 1 circuit failed Low Injector Solenoid Driver Cyl 3 circuit failed Low Calibration Incompatibility Error ECM hardware failure Injector Power Supply failed Low Sensor supply 1 circuit failed Low Sensor supply 1 circuit failed High Low Battery Voltage

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General information on troubleshooting Failure codes table

Values marked A: See Cummins shop manual. Failure code CC442 CC671 CC672 CC673 CC674 CC675 CC676 CC677 CC678 CC689 CC731 CC1117 CC1257 CC1376 CC1521 CC1522 CC1523 CC1524 CC1525 CC1526 CC1527 CC1554 CC1556 CC1618 CC2185 CC2186 D191KA D191KB Failure (Displayed on screen) High Battery Voltage Component in charge Action code E01 E01 E01 E03 E01 E01 E01 E01 E01 E01 Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system A A A A A A A A A A A A A A A A A A A A A A A A A A 40-182 40-184

Engine (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #1 (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #2 (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #3 (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #4 (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #5 (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #6 (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #7 (Cummins) Exhaust Temp. sensor circuit failed low Left Engine Bank #8 (Cummins) Engine Engine crankshaft speed failed (Cummins) Engine speed misalignment Camshaft and Engine Crankshaft (Cummins) Engine Power Lost with Ignition On (Cummins) Engine Module ID Input State Error (Cummins) Engine Engine camshaft speed failed (Cummins) Exhaust temp. sensor circuit failed High - Left Engine Bank #2 (Cummins) Engine Exhaust temp. sensor circuit failed High - Left (Cummins) Bank #3 Exhaust temp. sensor circuit failed High - Left Engine Bank #4 (Cummins) Exhaust temp. sensor circuit failed High - Left Engine Bank #5 (Cummins) Exhaust temp. sensor circuit failed High - Left Engine Bank #6 (Cummins) Exhaust temp. sensor circuit failed High - Left Engine Bank #7 (Cummins) Exhaust temp. sensor circuit failed High - Left Engine Bank #8 (Cummins) Engine Injector Solenoid Driver Cyl 13 circuit failed Low (Cummins) Engine Injector Solenoid Driver Cyl 15 circuit failed Low (Cummins) Exhaust temp. sensor circuit failed High - Left Engine Bank #1 (Cummins) Engine Sensor supply 4 circuit failed High (Cummins) Engine Sensor supply 4 circuit failed Low (Cummins) Boom Bucket & Neutral Output Relay Disconnection AJSS Boom Bucket & Neutral Output Relay hot short AJSS

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General information on troubleshooting Failure codes table

Failure code D19MKA

Failure (Displayed on screen) SW pump PNC solenoid Relay (Disconnect/Short Circuit)

Component in charge Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Transmission Transmission Boom Bucket & AJSS Monitor Panel Monitor Panel Transmission Transmission Transmission Transmission Monitor Panel Transmission Transmission Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Transmission Boom Bucket & AJSS Boom Bucket & AJSS KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus KOMTRAX Plus Monitor Panel

Action code E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E03 E01 E03 E03 E03 E03 E03 E01 E03 E03 E03 E03 E03 E03 E03 E03 E01 E01 E01 E03 E03

Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system 40-186 40-188 40-190 40-192 40-193 40-195 40-197 40-199 40-202 40-204 40-206 40-208 40-210 40-212 40-214 40-216 40-218 40-220 40-222 40-224 40-226 40-228 40-230 40-232 40-234 40-236 40-238 40-240 40-236 40-237 40-239

D19MKY SW pump PNC solenoid Relay hot short D19MMA SW pump PNC solenoid circuit 1 Failure D19MMB SW pump PNC solenoid circuit 2 Failure D5ZHKA Starting Switch C signal circuit (Disconnect/Short Circuit)

D5ZHKB Starting Switch C signal circuit Hot short D5ZHKZ Strarting Switch C signal circuit failure D5ZHL6 Ignition C terminal Circuit Failure

DAF5KP Monitor Panel 5 V source sys Error DAFRKR Communication Lost Monitor Panel Controller DAQ0KK Drop in Transmission Controller Main Power Source Drop in Transmission Controller Solenoid Power Source

DAQ0KT Nonvolatile Memory Writing Data Abnormal DAQ2KK

DAQRKR Communication Lost T/M Controller Defective Option Selection Data in TransmisDAQRMA sion DB2RKR Communication Lost Engine Controller DB90KK Drop in Work Controller Main Power Source DB90KT Nonvolatile Memory Writing Data Abnormal DB92KK Solenoid Voltage Failure (Work controller) DB95KX 5 V source sys Error (Work controller) Communication Lost Boom Bucket & Joy stick Controller Defective Option Selection Data in Boom DB9RMA Bucket Controller DB9RKR DB9RMC Communication Lost (Work Controller) DBB0KK VHMS source voltage Error DBB0KQ VHMS Connector Mismatch Abnormality in VBAT voltage(VHMS DBB3KK VBAT<10V) DBB5KP VHMS 5 V source sys Error DBB6KP VHMS 24 V source sys Error DBB7KP VHMS 12 V source sys Error DBBQMC Communication Lost (VHMS CAN0) DBBRKR Communication Lost VHMS Controller

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General information on troubleshooting Failure codes table

Failure code

Failure (Displayed on screen)

Component in charge KOMTRAX Plus Transmission Boom Bucket & AJSS Boom Bucket & AJSS Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Monitor Panel Transmission Transmission Transmission Transmission Transmission Transmission KOMTRAX Plus Transmission Transmission Transmission Monitor Panel Monitor Panel Monitor Panel Monitor Panel KOMTRAX Plus

Action code E03 E01 E01 E01 E01 E01 E01 E03 E01 E01 E01 E01 E01 E03 E03 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01

Reference Category of record document page Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system 40-240 40-242 40-243 40-245 40-254 40-256 40-258 40-260 40-262 40-264 40-266 40-268 40-270 40-272 40-274 40-276 40-278 40-280 40-282 40-284 40-286 40-288 40-281 40-283 40-284 40-286 40-288 40-300 40-302 40-304 40-306 40-308

DBBRMC Communication Lost (VHMS CAN1) DD10KX Verification Mode SW Failure DD1ALD Remote positioner upper side set sw failure DD1BLD Remote positioner lower side set sw failure DDA7L4 Throttle Lock Input signal Short Circuit DDA8KB Throttle Lock (set/accelerator) switch Short Circuit Throttle Lock (set/decelerator) switch Short CirDDA9KB cuit DDB6L4 Neutral Signal Malfunction DDD7KA Speed control dial circuit (Low Voltage) DDD7KB Speed control dial circuit (High Voltage) DDDBKA Traction control dial circuit (Low Voltage) DDDBKB Traction control dial circuit (High Voltage) DDE5MA Emergency steering signal Failure DDK4KA AJSS F/N/R Input Signal Disconnection DDK4KB AJSS F/N/R Input Signal Short Circuit Joystick Shift up/down SW circuit (Disconnect/Short Circuit) Steering lock detector pressure switch signal DDP5KA circuit Disconnect DDK5L4 DDT4LD T/M Cut Off set switch signal short circuit DDW9LD Kickdown Switch Short Circuit DGE5KX Ambient air temp Sensor Failure DGF1KA Transmission Oil Temperature sensor signal Disconnect Abnormality in Transmission Oil Temperature DGF1KB sensor Short Circuit Transmission Oil Temperature sensor Failure DGF1KX (For Check)

DGH2KX Hydraulic oil temp. sensor circuit failure DGR2KA Brake oil temp. sensor circuit Disconnection DGR2KX Brake oil temp. sensor circuit failure DGT1KX T/C oil temp. sensor circuit failure DH20KX Torque converter pressure sensor circuit DH21KA Loader pump oil press sensor (Disconnect/Short Circuit)

Boom Bucket & AJSS Boom Bucket & DH21KB Loader pump oil press sensor hot short AJSS Boom Bucket & DHPCKA Boom bottom press. (Disconnect/Short Circuit) AJSS DHPCKX Boom bottom press. sensor circuit failure Monitor Panel

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General information on troubleshooting Failure codes table

Failure code

Failure (Displayed on screen)

Component in charge Boom Bucket & AJSS Monitor Panel T/M Monitor Panel KOMTRAX Plus KOMTRAX Plus

Action code E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E03 E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E01

Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system 40-310 40-312 40-314 40-316 40-318 40-320 40-322 40-324 40-326 40-328 40-330 40-332 40-334 40-336 40-338 40-325 40-326 40-328 40-329 40-330 40-331 40-333 40-349 40-352 40-354 40-356 40-358 40-359 40-362 40-363 40-364

DHPCKY Boom bottom press. hot short DHPDKX Boom head press. sensor circuit failure DHT1KX T/M Cut Off pressure sensor signal Disconnect DHT2L6 T/M oil filter sensor circuit failure

DHT3KX Transmission main pressure sensor circuit DHT4KX Main PPC oil pressure sensor circuit

DHT5KX Torque converter intake pressure sensor circuit KOMTRAX Plus DHT8KX Steering Oil Press. Sensor Failure DHTAKX KOMTRAX Plus

Transmission lubrication pressure sensor cirKOMTRAX Plus cuit Modulation clutch pressure sensor circuit DisDHTBKA Transmission connect Modulation clutch pressure sensor signal short DHTBKB Transmission circuit DHU2KA F Brake Oil press Sensor Disconnect DHU2KB F Brake Oil press Sensor Hot short DHU2KX F Brake Oil press Sensor Failure DHU3KA R Brake Oil press Sensor Disconnect DHU3KB R Brake Oil press Sensor Hot short DHU3KX R Brake Oil press Sensor Failure DJF1KA Fuel level sensor circuit Disconnection Steering lever angle sensor (Disconnect/Short DK30KA Circuit) DK30KY DK59KA DK59KY DK59L8 DK5AKA DK5AKY DK5BKA DK5BKY DK5BL8 DK5CKA DK5CKY DKA0KA Transmission Transmission KOMTRAX Plus Transmission Transmission KOMTRAX Plus Monitor Panel

Boom Bucket & AJSS Boom Bucket & Steering lever angle sensor circuit hot short AJSS Boom lever potentiometer (main) (DisconBoom Bucket & nect/Short Circuit) AJSS Boom Bucket & Boom lever potentiometer (main) hot short AJSS Boom Bucket & Boom lever potentiometer (main & sub) failure AJSS Boom lever potentiometer (sub) (DisconBoom Bucket & nect/Short Circuit) AJSS Boom Bucket & Boom lever potentiometer (sub) hot short AJSS Bucket lever potentiometer (main) (DisconBoom Bucket & nect/Short Circuit) AJSS Boom Bucket & Bucket lever potentiometer (main) hot short AJSS Boom Bucket & Bucket lever potentiometer (main & sub) failure AJSS Boom Bucket & Bucket lever potentiometer (sub) (DisconAJSS nect/Short Circuit) Boom Bucket & Bucket lever potentiometer (sub) hot short AJSS Boom Bucket & Boom angle sensor (Disconnect/Short Circuit) AJSS

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Values marked *: "E-POCV" on monitor screen refers to "ECMV" Failure code Failure (Displayed on screen) Component in charge Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & AJSS Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission KOMTRAX Plus Monitor Panel Monitor Panel Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Action code E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E03 E01 E03 E03 E03 E03 E01 E01 E01 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 Reference Category of record document page Electrical system Electrical system Mechanical system Electrical system Electrical system Mechanical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system 40-366 40-368 40-370 40-372 40-373 40-374 40-375 40-360 40-361 40-363 40-364 40-366 40-386 40-388 40-390 40-392 40-394 40-396 40-397 40-398 40-400 40-402 40-404 40-387 40-388 40-389 40-390 40-409 40-410 40-411 40-412

DKA0KX Boom angle sensor circuit failure DKA0KY Boom angle sensor circuit hot short DKA0L0 Boom angle sensor failure DKD0KA Frame angle sensor (Disconnect/Short Circuit) DKD0KY Frame angle sensor circuit hot short DKD0KZ Frame and steering angle sensor failure DKH0KA Angle sensor circuit(FR) Disconnect DKH0KB Angle sensor circuit(FR) Hot short DKH1KA Angle sensor circuit(LR) Disconnect DKH1KB Angle sensor circuit(LR) Hot short DLE2KA Engine Speed Sensor Disconnection DLE2LC Engine Speed Sensor Short Circuit DLF6LC Tire speed sensor circuit DLFAKA Mod/c Output Speed Sensor Disconnect DLFALC Mod/c Output Speed Sensor Short Circuit DLT4KB Output Shaft Speed Sensor (1) Short Circuit DLT4KX Output Shaft Speed Sensor (1) Disconnection Transmission cut off indicator Output short cirDT20KB cuit DT21KB Speed Control indicator Output short circuit DUM8KB VHMS Operation lamp Short Circuit DV00KY Buzzer circuit hotshort(for usually) DV01KY Buzzer circuit hotshort(for special) DW23KA DW23KB DW23KY DW24KA DW24KB DW24KY DW25KA DW25KB DW25KY T/M E-POCV (F bypass) Solenoid Disconnection (*) T/M E-POCV (F bypass) Solenoid Short Circuit(*) T/M E-POCV (F bypass) Solenoid circuit Hot short (*) T/M E-POCV (R bypass) Solenoid Disconnection (*) 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 Disconnection (*) T/M E-POCV (1st bypass) Solenoid Short Circuit (*) T/M E-POCV (1st bypass) Solenoid circuit Hot short (*)

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General information on troubleshooting Failure codes table

Values marked *: "E-POCV" on monitor screen refers to "ECMV" Failure code Failure (Displayed on screen) Component in charge Action code E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E01 E01 E01 Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system 40-413 40-414 40-415 40-416 40-417 40-400 40-401 40-402 40-403 40-404 40-405 40-406 40-407 40-408 40-409 40-410 40-411 40-412 40-431 40-432 40-433 40-434 40-435 40-436 40-437 40-438 40-439 40-440 40-441 40-428

Boom Bucket & AJSS Boom Bucket & DW4PKB Boom EPC solenoid (raise1) short circuit AJSS Boom Bucket & DW4PKY Boom EPC solenoid (raise1) hot short AJSS Boom Bucket & DW4QKA Boom EPC solenoid (take down1) disconnection AJSS Boom Bucket & DW4QKB Boom EPC solenoid (take down1) short circuit AJSS Boom Bucket & DW4QKY Boom EPC solenoid (take down1) hot short AJSS Boom Bucket & DW4RKA Bucket tilt1 EPC solenoid disconnection AJSS Boom Bucket & DW4RKB Bucket tilt1 EPC solenoid short circuit AJSS Boom Bucket & DW4RKY Bucket tilt1 EPC solenoid hot short AJSS Boom Bucket & DW4SKA Bucket dump1 EPC solenoid disconnection AJSS Boom Bucket & DW4SKB Bucket dump1 EPC solenoid short circuit AJSS Boom Bucket & DW4SKY Bucket dump1 EPC solenoid hot short AJSS Boom Bucket & DW5PKA Boom EPC solenoid (raise2) disconnection AJSS Boom Bucket & DW5PKB Boom EPC solenoid (raise2) short circuit AJSS Boom Bucket & DW5PKY Boom EPC solenoid (raise2) hot short AJSS Boom Bucket & DW5QKA Boom EPC solenoid (take down2) disconnection AJSS Boom Bucket & DW5QKB Boom EPC solenoid (take down2) short circuit AJSS Boom Bucket & DW5QKY Boom EPC solenoid (take down2) hot short AJSS Boom Bucket & DW5RKA Bucket tilt2 EPC solenoid disconnection AJSS Boom Bucket & DW5RKB Bucket tilt2 EPC solenoid short circuit AJSS Boom Bucket & DW5RKY Bucket tilt2 EPC solenoid hot short AJSS Boom Bucket & DW5SKA Bucket dump2 EPC solenoid disconnection AJSS Boom Bucket & DW5SKB Bucket dump2 EPC solenoid short circuit AJSS Boom Bucket & DW5SKY Bucket dump2 EPC solenoid hot short AJSS T/M E-POCV (R drain) Solenoid Disconnection DWJ2KA Transmission (*) DW4PKA Boom EPC solenoid (raise1) disconnection DWJ2KB T/M E-POCV (R drain) Solenoid Short Circuit (*) DWJ2KY Transmission T/M E-POCV (R drain) Solenoid circuit Hot short Transmission (*) Work equipment neutral lock solenoid disconBoom Bucket & DWM1KA nection AJSS Work equipment neutral lock solenoid short cir- Boom Bucket & DWM1KB cuit AJSS Boom Bucket & DWM1KY Work equipment neutral lock solenoid hot short AJSS

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Values marked *: "E-POCV" on monitor screen refers to "ECMV" Failure code DWN6KA Failure (Displayed on screen) Component in charge Action code E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E01 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 E03 Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system Electrical system 40-430 40-432 40-434 40-436 40-438 40-440 40-442 40-444 40-446 40-452 40-453 40-454 40-455 40-457 40-459 40-461 40-463 40-465 40-467 40-469 40-471 40-473 40-475 40-477 40-479 40-481 40-483 40-485 40-487 40-489 40-491

Boom Bucket & AJSS Boom Bucket & AJSS Boom Bucket & DWN6KY Magnet detent solenoid (Boom raise) hot short AJSS Magnet detent solenoid (Boom float) disconnec- Boom Bucket & DWN7KA tion AJSS Magnet detent solenoid (Boom float) short cirBoom Bucket & DWN7KB cuit AJSS Boom Bucket & DWN7KY Magnet detent solenoid (Boom float) hot short AJSS Magnet detent solenoid (Bucket tilt) disconnec- Boom Bucket & DWN8KA tion AJSS Boom Bucket & DWN8KB Magnet detent solenoid (Boom tilt) short circuit AJSS Boom Bucket & DWN8KY Magnet detent solenoid (Boom tilt) hot short AJSS Boom Bucket & DWNAKA NC solenoid disconnection AJSS Boom Bucket & DWNAKB NC solenoid short circuit AJSS Boom Bucket & DWNAKY NC solenoid hot short AJSS Loader pump solenoid Relay (Disconnect/Short Boom Bucket & DXA1KA Circuit) AJSS Boom Bucket & DXA1KY Loader pump solenoid Relay hot short AJSS Loader pump solenoid Relay (Disconnect/Short Boom Bucket & DXA1MA Circuit) AJSS Boom Bucket & DXF0KA AJSS EPC solenoid disconnection AJSS Boom Bucket & DXF0KB AJSS EPC solenoid short circuit AJSS DXH4KA T/M E-POCV (1st) Solenoid Disconnection (*) DXH4KB T/M E-POCV (1st) Solenoid Short Circuit (*) DXH4KY T/M E-POCV (1st) Solenoid circuit Hot short (*) DXH5KA T/M E-POCV (2nd) Solenoid Disconnection (*) DXH5KB T/M E-POCV (2nd) Solenoid Short Circuit (*) DXH5KY T/M E-POCV (2nd) Solenoid circuit Hot short (*) DXH6KA T/M E-POCV (3rd) Solenoid Disconnection (*) DXH6KB T/M E-POCV (3rd) Solenoid Short Circuit (*) DXH6KY T/M E-POCV (3rd) Solenoid circuit Hot short (*) DXH7KA T/M E-POCV (R) Solenoid Disconnection (*) DXH7KB T/M E-POCV (R) Solenoid Short Circuit (*) DXH7KY T/M E-POCV (R) Solenoid circuit Hot short (*) DXH8KA T/M E-POCV (F) Solenoid Disconnection (*) DXH8KB T/M E-POCV (F) Solenoid Short Circuit (*) Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission Transmission

Magnet detent solenoid (Boom raise) disconnection Magnet detent solenoid (Boom raise) short cirDWN6KB cuit

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General information on troubleshooting Failure codes table

Values marked *: "E-POCV" on monitor screen refers to "ECMV" Failure code Failure (Displayed on screen) Component in charge Transmission Transmission Transmission Transmission Transmission Action code E03 E03 E03 E03 E01 Reference Category of record document page Electrical system Electrical system Electrical system Electrical system Electrical system 40-493 40-494 40-495 40-496 40-497

DXH8KY T/M E-POCV (F) Solenoid circuit Hot short (*) DXHPKA T/M E-POCV (MOD/C) Solenoid Disconnection (*) T/M E-POCV (MOD/C) Solenoid Short Circuit to 24 V (*)

DXHPKB T/M E-POCV (MOD/C) Solenoid Short Circuit (*) DXHPKY

DXHPMA T/M E-POCV (MOD/C) Solenoid Malfunction (*)

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)".)

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Symptom and troubleshooting numbers

No. Symptom of failure Action code/Failure code 1 Action code and failure code are displayed on machine monitor. 2 Failure code is displayed on mechanical system abnormality record. 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). 5 Turning or response of steering is poor. 6 AJSS lever is hard to operate. 7 Steering shakes or jolts. 8 Wheel brake does not work at all or is weak. 9 Lift arm speed is low or lift arm rising force is insufficient. 10 Shock is large when lift arm stops. 11 Hydraulic oil temperature rises too high (overheating). Symptom related to monitor 12 Machine monitor does not operate. Service meter does not proceed, or service meter proceeds while engine 13 stopped. 14 Buzzer operated by monitor panel controller does not sound. Symptom related other electrical system 15 LED for remote positioner "RAISE" or "LOWER" does not light up. 16 Open circuit or ground fault in check lamp system. 17 Turn signal lamp does not light up. 18 Defective parking lamp. 19 Defective front working lamp. 20 Defective rear working lamp. 21 Night lighting does not light up. 22 Defective auto-greasing system. E-1 E-2 E-4 E-5 E-6 E-7 E-8 E-11 40-499 40-500 40-502 40-504 40-506 40-508 40-510 40-516 E-3 E-9 E-10 40-501 40-512 40-514 H-1 H-2 H-3 H-4 H-5 H-6 H-7 H-8 40-702 40-705 40-708 40-710 40-712 40-714 40-717 40-718 Perform troubleshooting for failure code Troubleshooting Index Page

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Information in troubleshooting table

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(Rev. 2010/03) a The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before performing troubleshooting, understand that information fully.
User code Display on machine monitor Detail of failure Action of machine monitor or controller Problem on machine Related information Failure code Display on machine monitor Failure Failure name displayed on the Abnormality Record screen of the machine monitor

Description of the failure detected by the machine monitor or controller Action to be taken to protect the system and equipment when the machine monitor or controller detects a trouble Problem that appears on machine as result of action (above) taken by machine monitor or controller Information related to detected failure or troubleshooting Cause

Procedure, measuring location, criteria and remarks <Details of description> q Procedure q Measuring location Defective component a "Between A and B" means the measurement of voltage, resistance or others between terminals A and B. q Criteria to judge probable causes (normal value) q Remarks for judgment <How to use troubleshooting sheet> q Perform troubleshooting procedures in numerical order. Open or short circuit in wiring 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, proceed 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> (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 (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 (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, disconnect the connector, and insert T-adapter between the male and female connectors. q When "male" or "female" is indicated with a connector number, disconShort 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. Defective controller q Connect the negative (-) lead to a pin or wire indicated second.

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Related circuit diagram

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This is the excerpted circuit diagram related to troubleshooting 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 machine. q NO: Normally Open q NC: Normally Closed

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General information on troubleshooting 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 amplifiers 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".

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List of pressure sensor measuring locations and reference values

Sensor Measuring location at sensor pin R2: Between (1) and (3) Ambient pressure sensor R1: Between (2) (+) and (1) (-) R1: Between (1) (+) and (2) (-) Measured internal resistance of sensor (Reference value) Approx. 3.2 kz Approx. 4.6 kz Approx. 2.9 kz Remarks Sensor is common to engine models 95, 125, 140, 170 and 12 V140 If polarities are reversed, resistance value changes.

*: In addition to the above, when measuring R2', disconnect the following:(See circuit diagram related to failure 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 Sensor unit (Measuring location on sensor pin side connector) R2: Between (1) and (3) Ambient pressure sensor R1: Between (2) (+) and (1) (-) R1: Between (1) (+) and (2) (-) Measured value Sensor + Wiring harness (Measuring location on harness side connector of engine controller) R2': Between (37) and (38) (*) R1': Between (3) (+) and (38) (-) R1': Between (38) (+) and (3) (-) Measured value

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General information on troubleshooting Layout drawing of connector pins

Layout drawing of connector pins

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(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.

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General information on troubleshooting Connector list and layout

Connector list and layout

Connector No. A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 A11 A12 A13 A14 A16 A17 A18 A19 ACC AL01 AL02 AL03 AL04 AR01 AR02 AR03 AR04 ASS B06 B07 B08 B09 B BR BR1 C C1 C2 C01 C02 C03 C04 C05 C05 C06 C07 C08 C09 C10 C11 C12 C13 C14 C15 C16 C17 C18 Connector type Relay Relay Relay Relay Relay Relay Relay Relay X M SWP M YAZAKI X SWP SWP Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal SWP DT2 DT2 DT2 DT2 Terminal Terminal DT2 Terminal HD36-24 HD36-24 M 08027 08027 One-pin connector 08032 Terminal M One-pin connector One-pin connector One-pin connector One-pin connector 08027 SWP 08027 SWP YAZAKI PA SWP SWP SWP Number of pins 4 4 4 4 4 4 4 4 2 2 6 6 2 2 12 16 8 8 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1 6 1 23 31 6 4 4 1 1 1 2 1 1 1 1 6 6 4 6 9 6 6 6 Location Blower relay(Main) Blower relay(HI) Blower relay(M2) Cond relay Blower relay(M1) MAG.C.relay Cond HI(1)relay Cond HI(2)relay REC & FRE air servomotor Thermistor Air mix servo motor Blower motor & resistor Air conditioner blower relay(M1) Air condenser Hi/Lo switch Air conditioner control amp Air conditioner control amp Air conditioner left air flow servomotor Air conditioner right air flow servomotor Starter switch ACC terminal Battery relay LH Battery relay LH Battery relay LH Battery relay LH Battery relay RH Battery relay RH Battery relay RH Battery relay RH Air suspention seat Dust indicator 1 Dust indicator 2 Dust indicator 3 Dust indicator 4 Starter switch B terminal Starter switch BR terminal Intermediate connector Starter switch C terminal Engine controller Engine controller Front wiper motor Left wiper motor Right wiper motor Cigarette lighter Cigarette lighter GND Air conditioner Intermediate connector Intermediate connector Intermediate connector Intermediate connector Front wiper switch Rear wiper switch Front wiper change switch Fog lamp switch(If equipped.) AM/FM radio Stairway lamp switch Rear side work lamp switch Warning lamp (beacon) switch (If equipped.) Address AO-9 AP-9 AP-9 AP-9 AO-9 AO-9 AO-9 AP-9 AE-9 AU-2 AU-2 AT-1 AT-6 AS-6 BE-8 BE-8 BE-1 BC-4 Y-5 V-3 V-3 T-9 V-3 P-8 P-8 R-9 Q-9 AR-7 H-9 G-9 G-9 G-9 Y-4 Y-4 I-2 Y-4 S-9 T-9 BC-3 BG-2 BC-5 Y-7 AA-9 BD-8 BH-5 BD-8 BC-7 BC-7 BC-7

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Connector No. C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 CAN1 CB1 CB2 CB3 CB4 CB5 CB6 CB7 CB8 CB9 CB10 CB11 CB12 CB13 CB14 CB1A CB2A CB3A CB4A CB5A CB6A CB7A CB8A CB9A CB10A CB11A CB12A CB13A CB14A CB1B CB2B CB3B CB4B CB5B CB6B CB7B CB8B CB9B CB10B CB11B CB12B CB13B CB14B CHK CL1

Connector type 08027 08027 Terminal Terminal 08027 Terminal DT2 M M M 08027 M DT2 DT2 DT2 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD3 DTHD3 DTHD3 DTHD3 Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT2 DRC

Number of pins 2 2 1 1 2 1 2 6 2 2 2 2 2 2 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 40

Location Speaker LH Speaker RH Door switch RH(room lamp) Door switch LH(room lamp) Room lamp GND Intermediate connector Rear wiper motor Front work lamp RH Front work lamp LH Room lamp Stairway lamp RH Warning lamp (beacon) (If equipped.) Warning lamp (beacon) (If equipped.) Resistor Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker Circuit breaker N MODE(STD) Intermediate connector

Address BH-7 BF-8 BD-8 BH-5 BH-2 BF-8 BH-4 BC-6 BG-2 BE-9 BG-8 BG-8 BE-9 V-1 V-1 V-1 V-2 V-2 V-1 V-1 V-1 U-2 V-2 U-1 U-1 U-2 U-2 M-9 M-9 M-9 N-9 N-9 N-9 N-8 M-8 M-9 N-9 N-8 M-8 M-8 M-8 M-9 M-9 M-9 N-9 N-9 N-8 N-8 M-9 M-9 N-9 N-8 N-8 M-8 M-8 AO-1 AB-1

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General information on troubleshooting Connector list and layout

Connector No. CL2 CL3 DIO DL1 E3 E03 E04 E05 E10 E11 E13 E14 E15 E16 E17 E18 E20 E21 E22 E23 E24 E25 E26 E27 E27 EM01 EM02 EM6 EM7 EM8 EM9 E28 E29 EM1 EM2 EM3 EM4 EM5 ER1 ER2 ER3 ER4 ER5 ER6 ER7 ER8 ER9 ER10 ER11A ER11B ER12 ER13 ER14 ER15 ETH1 ETH2 ETH3 F01 F02

Connector type DT2A DT2 MS310A A4S-5S DT2 Terminal DT2 Terminal DT2 DT2 Terminal DT2 DT2 08027 DT2 Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal Terminal DT2 DT2 DT2A Terminal Terminal Terminal Terminal DT1 DT2 DT2 DTHD3 DTHD3 DTHD3 DTHD3 DTHD4 DTHD4 DT2 DT2 DT2 DTHD3 DTHD3 DTHD3 Terminal One-pin connector DT2 One-pin connector DT1 DT1

Number of pins 12 6 2 5 3 1 6 1 2 2 1 3 3 6 2 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 2 2 12 1 1 1 1 6 6 3 1 1 1 1 1 1 2 2 2 1 1 1 1 1 2 1 6 6

Location Intermediate connector Intermediate connector Diode FOR KOMATSU PC Engine controller Alternator Intermediate connector Alternator Compressor magnet switch Diode Engine GND Intermediate connector Intermediate connector Regulator Intermediate connector GND Starter relay Starter relay Starter relay Starter relay Conventional starter Conventional starter Conventional starter Conventional starter Enginr oil level sensor Emergency engine stop switch Emergency engine stop switch Emergency engine stop rear RH Emergency engine stop rear RH Emergency engine stop rear LH Emergency engine stop rear LH Intermediate connector Intermediate connector Intermediate connector Emergency engine stop(Front RH) Emergency engine stop(Front RH) Emergency engine stop(Front LH) Emergency engine stop(Front LH) Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Battery disconnect switch Ether inj. Solenoid Diode Ether inj. Solenoid Intermediate connector Intermediate connector

Address AA-1 AA-1 Y-5 S-9 L-6 L-5 J-3 L-7 H-1 X-3 X-3 I-2 X-1 S-9 W-2 W-2 W-3 W-2 H-1 H-1 W-6 I-2 W-5 AK-7 AK-7 G-9 G-9 K-3 L-3 W-3 W-6 N-1 R-1 R-1 M-1 M-1 W-1 W-2 X-1 X-3 X-3 X-2 X-2 X-1 X-1 W-2 W-1 W-1 G-1 G-1 G-1 J-2 J-2 A-5 D-1

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Connector No. F04 F05 F06 F07 F09 F11 F12 F13 F14 F15 F20 F21 F23 FC01 FC02 FC03 FC04 FC05 FC06 FC07 FC09 FC10 FC11 FC12 FC13 FC14 FC15 FC16 FC17A FC17B FC18 FC19 FC20 FC21 FC22 FCL1 FCL2 FH1 FH2 FH3 FH4 FCL1 FCL2 FL1 FL2 FR1 FR2 FUSE1 FUSE2 FUSE3 G01 G01 G02 G02 G03 G04 G04 G14 GND1A

Connector type DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 Terminal AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 SWP SWP SWP SWP 08027 X X One-pin connector One-pin connector SWP DT2 DT2 SWP SWP DT1,DT2B DT2 DT2 DT2 DT2 DT1,DT2B HD-26886,HD-26096 HD-25886,HD-25096 HD-86886,HD-86086 HD-46882,HD-46082 Fuse box Fuse box Fuse box DT2A DT2A DT2 DT2 DT2 DT2 DT2 Terminal Terminal

Number of pins 3 3 3 2 2 2 2 3 3 3 1 2 2 20 18 12 18 12 12 14 6 6 6 6 4 7 3 3 1 1 6 2 6 6 6 70 8 2 2 2 2 70 8 14 14 23 21 30 30 30 8 8 8 3 2 2 3 1 1

Location Boom angle switsh Bucket positioner max tilt Boom bottom pressure sensor Horn Horn Work lamp (OP) Work lamp (OP) Boom head pressure sensor Wheel speed sensor Chassis GND Horn Horn Monitor panel controller Monitor panel controller Monitor panel controller Monitor panel controller Monitor panel controller Monitor panel controller Monitor panel controller Parking brake switch Load meter mode switch LCD/LED tuning switch Service meter switsh Lighting mode switch Hazard switch Variable traction control Vehicle speed Diode Diode Brake pedal cancel switch RH Idle/throttle validation switch Idle/throttle validation switch LCD/LED change switch Active working switch Intermediate connector Intermediate connector Diode Diode Diode Diode Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Fuse box Fuse box Fuse box Intermediate connector Intermediate connector Intermediate connector Back buzzer relay Back buzzer RH Back buzzer LH Stairway lamp switch GND GND

Address A-6 A-3 E-1 D-1 A-4 A-2 B-1 A-4 E-1 A-2 E-9 C-1 A-5 Y-4 Y-3 Y-3 Y-2 Z-2 AA-1 AC-1 AC-1 AP-1 AP-1 Z-2 AA-1 Z-2 Y-3 AC-1 AC-1 AB-1 AJ-6 AJ-5 AI-2 AJ-4 AR-9 AR-9 AC-9 L-7 L-7 L-6 L-4 K-3 AI-8

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General information on troubleshooting Connector list and layout

Connector No. GND1B GND2 GR02 GR1 GR2 GR03 GR03 GR03 GR04 GR04 GR04 GR05 GR05 GR05 GR06 GR06 GR06 GR07 GR07 GR07 GR08 GR09 GR10 GR11 GR12 GR13 GR14 GR15 GR16 GR17 GR6 GRE1 HR1 HR2 HR6 HR10 HR14 HR15 HR16 HR17 HR18 HR19 HR20 HR21 HR22 HR23 HR24 HR25 HR26 HR27 HR28 HR29 HR30 HR31 HR32 HR33 HS1 HS2 HS3

Connector type Terminal Terminal DT2 DT1A DT2A DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT1 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2

Number of pins 1 1 8 12 8 6 6 6 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 2 2 2 2 2 2 6 4 2 2 2 2 2 3 3 2 2 2 3 3 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3

Location GND GND Intermediate connector Intermediate connector Intermediate connector Rear combination lamp (LH) Rear combination lamp (RH) Intermediate connector(OP) Rear back lamp (LH) Rear back lamp (RH) Back lamp (OP) Rear work lamp LH Rear work lamp RH Work lamp (OP) Rear HID lamp (LH) Rear HID lamp (RH) Work lamp (OP) Rear work lamp LH Rear work lamp RH Work lamp (OP) Turn signal lamp Stop & signal lamp Engine room lamp switch LH Engine room lamp switch RH Rear side work lamp LH Rear side work lamp RH Star way lamp Engine room lamp LH Engine room lamp RH Coolant level sensor Intermediate connector Intermediate connector NC(Neutral)solenoid Diode Rear brake level Front brake level Parking brake solenoid Front brake oil pressure sensor Rear brake oil pressure sensor Emergency brake switch Emergency brake switch Emergency parking brake release solenoid Front brake pressure switch Rear brake pressure switch BBC CUT OFF SOLENOID BOOM RAISE EPC1 BOOM LOWER EPC1 BUCKET TILT EPC1 BUCKET DUMP EPC1 BOOM RAISE EPC2 BOOM LOWER EPC2 BUCKET TILT EPC2 BUCKET DUMP EPC2 SW PUMP PNC SOLENOID1 SW PUMP PNC SOLENOID2 ACTIVE POWER UP SOLENOID Hydraulic oil temperature sensor Hydraulic oil pressure sensor Steering oil pressure sensor

Address AI-8 AK-8 L-5 L-6 J-9 I-9 W-9,X-9 J-9 I-9 W-8,W-9 K-9 H-9 W-9,X-9 W-9,X-8 J-9 I-9 W-9,X-8 W-9,X-9 W-9,X-9 L-6 H-9 H-9 L-7 L-8 J-9 H-9 J-9 L-5 M-6 V-9 T-2 T-2 S-1 X-4 X-5 X-5 X-4 R-1 R-1 X-4 M-6 O-9 O-9 O-9 O-9 O-9 O-9 O-8 O-9 O-7 N-7 S-1 M-4 M-5 M-5

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Connector No. HS4 HS5 HS6 JB1 JB2 JC1 JC2 JC3 JC4 JC5 JC6 JC7 JE2 JE3 JE4 JE5 JF1 JF2 JF3 JF4 JF5 JF6 JG1 JG2 JG3 JG4 JG4 JG4 JG4 JG5 JG6 JGN JGN JGR2 JGR3 JHD JHD JL1 JL2 JL8 JL9 JL10 JL11 JL12 JM4 JM5 JM6 JM7 JR1 JR2 JR3 JR4 JR5 JR8 JR9 JR10 JR11 JR12 JR13

Connector type DT2 DT2 DT2 DT2B DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT1 DT2B DT2 DT2 DT1 DT1 DT2 DT2B DT1B DT1 DT1B DT2 DT2 DT1B DT1 DT2 DT2 DT1 DT2 DT2 DT2 DT1B DT1B DT2 DT2 DT2 DT2 DT2 DT2 DT2B DT1B DT1B DT2 DT2 DT2 DT2 DT1 DT2 DT1 DT2 DT2 DT1B DT2 DT2 DT2 DT2 DT2B

Number of pins 3 2 2 8 6 6 6 6 6 6 6 6 6 8 6 6 6 6 6 8 8 6 8 6 6 8 6 6 6 6 6 6 6 8 8 6 6 6 6 6 6 8 8 8 6 6 6 6 6 6 6 6 6 8 6 6 6 6 8

Location PPC oil pressure sensor Hydraulic oil level sensor Brake oil temperature sensor Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector

Address U-9 M-5 M-3 AQ-9 AQ-9 AN-9 AP-1 AO-1 AD-9 AD-9 K-8 L-8 L-8 P-9 P-9 AT-6 AR-8,AT-6 AC-9 AU-6 AT-6

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Connector No. JR14 JR15 JR16 JR17 JR18 JR20 JR21 JRA JRB JT1 JT2 JT3 JT4 JT6 L02 L03 L04 L05 L06 L07 L12 L16 L17 L42 L43 L44 L45 L46 L48 L49 L51 L52 L53 L54 L55 L56 L57 L58 L59 L60 L61 L65 L69 L71 L75 L81 L89 L101 L104 L106 L117 L118 L119 L120 L121 L122 L123 L124 L125

Connector type DT2 DT2 DT1B DT2 DT2 DT2 DT1 DT2 DT2 DT2B DT2B DT2B DT2B DT2B DRC KEYA DRC KEYA DRC KEYB DRC KEYA DRC KEYA DRC KEYB DT2 DT2 M M M 08027 Relay 08027 Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay DT2 SUMITOMO Relay Relay Relay Relay Relay Relay Relay Relay Relay Relay DT2 DT2

Number of pins 6 6 8 6 6 6 6 6 6 8 8 8 8 8 24 40 40 24 40 40 2 2 2 2 2 6 5 4 6 6 6 5 5 5 6 6 5 5 5 6 6 5 6 11 6 2 16 5 6 5 6 5 5 5 5 5 5 2 2

Location Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Transmission controller Transmission controller Transmission controller Boom bucket & AJSS controller Boom bucket & AJSS controller Boom bucket & AJSS controller Transmission cut off pressure sensor Fog lamp If equipped power Caution buzzer 1 Caution buzzer 2 Wiper relay Rear wiper Flasher unit relay Fog lamp relay Stairway lamp relay Side work lamp relay Hazerd relay Stop lamp relay Back up alarm Horn relay Head light relay Neutral relay Turn L relay Parking brake safety relay Front work lamp relay Rear work lamp relay Turn R relay SW pump relay Power window relay Front axle work lamp relay Stop lamp switch Emergency parking brake release switch Small lamp relay Turn & hazerd relay Beacon relay Side wiper change over relay Front washer relay Side washer relay Wiper Lo relay Wiper Hi relay Wiper INT"LH"relay Wiper INT"RH"relay Diode Diode

Address AL-9 AL-8 AK-7 AL-8 AM-9 AN-9 AC-1 AH-1 AD-9 AV-6 AO-1 AN-1 AS-6 AN-1 AS-7 AU-9 AS-8 AS-7 AS-9 AT-9 AT-9 AT-9 AS-8 AS-8 AT-9 AT-9 AT-9 AS-6 AS-9 AV-7 AU-9 AB-1 AG-9 AV-6 AU-9 AU-6 AU-9 AS-8 AU-9 AU-9 AV-9 AV-8 AV-8 AS-7 AS-7

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Connector No. L126 L127 L132 L133 L134 L135 L141 L142 L143 L145 L151 L160 LR1 LR2 LR3 LR4 LR5 LR6 LR7 LR8 LR9 LR10 LR11 LR12 LS1 LS2 LS3 LS4 LS6 LS7 M6 M7 MC1 MC2 MC3 MC4 MC5 MC6 MC7 MMS MT1 MT2 MT3 MT4 MT5 ORB1 ORB3 P1 PH1 PRE PWR1 PWR1 PWR2 PWR2 R01 R02 R03 R04 R05

Connector type DT2 Relay Relay Relay Relay Relay DT2 DT2 Relay M YAZAKI 7123-8322 Relay DT1B DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DTHD4 DT2C S(L) S(L) S(W) S(L) DTM DT2,DTM AMP070 AMP070 M DT2 DT2 M DT2 DT2 DT2 DT2C DT2 DT2 DT2 DT2 DT2 DRC KEYB HD36-24 DT2 DT2 One-pin connector One-pin connector One-pin connector One-pin connector DT2 DT2 DT2 DT2 DT2

Number of pins 2 5 5 5 5 5 3 3 5 4 2 8 12 1 1 1 1 1 1 1 1 40 70 12 12 16 12 12 12 2 18 12 2 2 2 2 2 2 2 12 3 3 3 3 3 40 1 16 2 2 1 1 1 1 2 2 2 2 2

Location Diode Steering neutral relay Dust ingicator 1 relay Dust ingicator 2 relay Dust ingicator 3 relay Dust ingicator 4 relay Tilt sensor pitching Tilt sensor rolling Buzzer 2 relay Dcconverter(24 V/12 V) 12 VDC socket Loader pump relay Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Multi monitor Multi monitor Resistor Diode Diode Resistor Diode Diode Diode MMS master link Transmission lubrication oil pressure sensor Transmission main oil pressure sensor Transmission outlet oil pressure sensor Transmission lubrication oil pressure sensor Transmission lubrication oil pressure sensor ORBCOM controller BNCP controller Engne controller Ambient air temperature sensor Pressure switch power window regulator RH power window regulator LH power window regulator RH power window regulator LH Transmission oil filter sensor Transmission oil filter sensor Diode Diode Fuel level sensor

Address AS-7 AV-9 AV-9 AV-8 AV-9 AV-9 AO-1 AV-8 AL-2 Y-5 AV-8 AH-1 AH-1 AG-1 AG-1 AF-1 AF-1 AE-1 AJ-7 AJ-7 AJ-5 AJ-3 AJ-2 AK-8 AK-6 AK-6 AK-5 AD-1 AD-1 AN-1 AN-1 AV-7 AP-1 AS-6 AR-1 AS-1 AE-9 AZ-3 AY-8 AX-7 AZ-8 BB-5 AC-1 T-9 O-9 Q-9 BC-4 BF-1 BC-4 BF-1 S-1 R-1 J-3

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General information on troubleshooting Connector list and layout

Connector No. R06 R07 R11 R12 R20 R22 R23 R24 R25 R26 R27 R30 R31 R32 R33 RA1 RA2 RA3 RA4 RA5 RA7 RA8 RA9 RA10 RA11 RA11 RE1 RE2 RES1 RF90 RT1 RT2 S01 S02 S03 S04 S05 S06 S07 S08 S09 S010 S011 S012 S014 S015 S018 S019 S020 S021 S022 S023 S024 S30 S31 SC1 SC2 SC3 STL

Connector type DT2 DT2 DT2 DT2 Terminal 08027 DT2 8027 DT2 08027 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2B DTHD4 DT1 DT2 DT2 DT2 DT2 Terminal DT2 Relay Relay DT2 DT2 HD-86086 HD-85086 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 SWP SWP SWP SWP SWP SWP SWP SWP SWP SWP DT2 DT2 DTM DT2A DT2A HD10-9-1939PE DT2

Number of pins 2 2 2 2 1 2 2 2 2 2 2 3 3 3 2 6 6 8 1 6 2 2 2 2 1 2 5 5 3 2 23 23 2 4 4 2 2 2 4 4 6 7 7 6 6 6 6 6 6 6 6 6 4 3 12 12 12 10 2

Location Diode Diode Emergency steering ingicate switch Emergency steering ingicate switch GND Front window sealed washer Diode Rear window sealed washer Diode Side window sealed washer Diode Condenser LH Condenser RH Frame angle sensor(Potentiometer) J/S EPC solenoid Intermediate connector Intermediate connector Intermediate connector Intermediate connector Intermediate connector Battery level sensor Battery level sensor Battery level sensor KOMTRAX Plus working lamp Battery disconnect switch KOMTRAX Plus working lamp Auto grease relay Auto grease relay Resistor For Grease level gauge(If equipped) Intermediate connector Intermediate connector Boom N lock switch Boom & bucket EPC lever Boom & bucket EPC lever Boom & bucket EPC lever Boom & bucket EPC lever Boom & bucket EPC lever Boom lever KDS & speed limit ON/OFF switch Bucket lever for load meter Auto digging switch Power window LH Power window RH Boom remote positioner set switch Auto grease switch Intermediate connector PRM lock switch Resume / deccel switch Auto manual switch Cut off set switch Turn signal switch Transmission cut off switch Work lamp switch AJSS lever angle sensor Joy stick lever switch Service connector Service connector Service connector S/T lock switch

Address M-3 M-1 I-2 X-7 X-7 X-7 N-7 O-7 M-4 M-4 U-2 O-7 T-2 T-9 U-2 U-3 P-8 O-7 V-9 V-8 R-9 Q-9 Q-9 AL-2 N-1 M-3,AW-6 M-2,AW-6 AL-9 AN-9 AL-9 Y-6 Y-6 AM-9 AM-9 Y-6 AA-9 Y-8 Z-8 AA-9 AB-9 AN-9 AB-9 AA-9 Z-9 Y-8 Y-7 Y-7 AI-8 AH-8 AG-9 AF-9 AR-7 AD-1

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Connector No. SV1 SW1 SW2 T1 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12 T13 T14 T15 T16 T17 T18 T19 T20 T21 T22 T23 T24 T25 TIM TURN TURN V1 V2A V2B V3A V3B V4A V4B V15 V16 V17 V18 V19 V20 VDL WORK1 WORK1 WORK2 WORK2 WORK3 WORK3

Connector type One-pin connector One-pin connector Terminal DT2 DT1 DT2 DT1 DT2 DT1 DT2 DT1 DT2 DT1 DT2 DT1 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 DT2 AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 AMP070 One-pin connector One-pin connector Terminal Terminal Terminal Terminal BENDIX DT2 DT2 DT2 DT2 DT2 DT2

Number of pins 4 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 10 3 3 20 18 12 18 12 14 10 1 1 1 1 1 1 5 2 2 2 2 2 2

Location Solenoid 1 Pressure switch Pressure switch GND 1st ECMV solenoid 1st fill switch 2nd ECMV solenoid 2nd fill switch 3rd ECMV solenoid 3rd fill switch Modulation clutch solenoid Modulation clutch fill switch R ECMV solenoid R fill switch F ECMV solenoid F fill switch Speed sensor Modulation clutch speed sensor Engine speed sensor Parking brake indicate switch Transmission oil temperature sensor 1st bypass solenoid R bypass solenoid F bypass solenoid R drain solenoid Torque converter oil temperature sensor Transmission oil temperature 2 sensor Timer Front combination lamp RH Front combination lamp LH KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller Diode(Green) Diode(Green) Wake up switch Wake up switch Wake up switch Wake up switch KOMTRAX Plus download box Head lamp RH Head lamp LH Head lamp RH Head lamp LH Head lamp RH Head lamp LH

Address P-9 Q-9 Q-9 AX-9 AX-9 AW-9 AW-9 AW-9 AW-9 BB-5 BB-7 BB-2 BB-2 BA-2 BB-2 AW-5 BB-7 AY-8 AZ-2 BB-4 AX-9 BA-2 BA-2 BA-2 F-9, BA-9 F-9, BB-4 Q-9 B-7 D-8 AK-6 AK-5 AK-4 AK-5 AK-6 AK-4 AK-5 O-1 O-1 O-1 O-1 O-1 O-1 Q-1 B-7 F-1 C-8 D-8 C-7 F-1

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General information on troubleshooting 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 column indicates a part number of harness checker assembly.
Number of pins T-adapter kit 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 Identificati-on symbol Out of kit

Part No.

Part name

799-601-2600 799-601-3100 799-601-3200 799-601-3380 799-601-3410 799-601-3420 799-601-3430 799-601-3440 799-601-3450 799-601-3460 799-601-3510 799-601-3520 799-601-3530 799-601-2910 799-601-3470 799-601-2710 799-601-2720 799-601-2730 799-601-2740 799-601-2950 799-601-2750 799-601-2760 799-601-2770 799-601-2780

T-box (for ECONO) T-box (for MS) T-box (for MS) Plate for MS (14-pin) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Adapter for BENDIX (MS) Case Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for MIC Adapter for ECONO Adapter for ECONO Adapter for ECONO Adapter for ECONO

21 37 37 24 24 17 17 5 10 5 17 19 14 5 13 17 21 9 2 3 4 8 12 8 12 16 12 60 1 2 3 4 6 8 12 14 16 1 2 3 4 6 8 MS-24P MS-24P MS-17P MS-17P MS-5P MS-10P MS-5P MS-17P MS-19P MS-14P MIC-5P MIC-13P MIC-17P MIC-21P MIC-9P ECONO 2P ECONO 3P ECONO 4P ECONO 8P ECONO 12P DLI-8P DLI-12P DLI-16P ECONO 12P

q q

q q q q q q q q

q q q q q q q q q q

q q q q q q q q q

q q q q q q q q q q q q q q

q q q

799-601-2790 Adapter for ECONO 799-601-2810 Adapter for DLI 799-601-2820 Adapter for DLI 799-601-2830 Adapter for DLI 799-601-2840 Extension cable (ECONO type) 799-601-2850 799-601-4350 799-601-4360 799-601-7010 799-601-7020 799-601-7030 799-601-7040 799-601-7050 799 -601-7060 799-601-7310 799-601-7070 799-601-7320 799-601-7080 799 -601-7090 799-601-7110 799-601-7120 799-601-7130 799-601-7340 Case T-box (for DRC 60, ECONO) Case Adapter for X (T-adapter) Adapter for X Adapter for X Adapter for X Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for SWP Adapter for M (T-adapter) Adapter for M Adapter for M Adapter for M Adapter for M Adapter for M

q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q

X2P X3P X4P SW6P SW8P SW12P SW14P SW16P M2P M3P M4P M6P M8P

q q q q q

q q q q q

q q q q q q

q q

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General information on troubleshooting T- branch box and T- branch adapter table

Number of pins

T-adapter kit 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 Identificati-on symbol Out of kit

Part No.

Part name

799-601-7140 799-601-7150 799-601-7160 799-601-7170 799-601-7330 799-601-7350 799-601-7180 799-601-7190 799-601-7210 799-601-7220 799-601-7230 799-601-7240 799-601-7270 799-601-7510 799-601-7520 799-601-7530 799-601-7540 799-601-7550 799-601-7360 799-601-7370 799-601-7380 799-601-9010 799-601- 9020 799-601-9030 799-601-9040 799-601-9050 799-601-9060 799-601-9070 799-601-9080 799-601-9090 799-601-9110 799-601-9120 799-601-9130 799-601-9140 799-601-9210 799-601-9220 799-601-9230 799-601-9240 799-601-9250 799-601-9260 799-601-9270 799-601-9280 799-601-9290 799-601-9310 799-601-9320 799-601-9330 799-601-9340 799-601-9350 799-601-9360 799-601-9410*

Adapter for M Adapter for S (White) Adapter for S (Blue) Adapter for S (Blue) Adapter for S (White) Adapter for S (White) Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Adapter for AMP040 Short connector for X Case Case Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for 070 Adapter for relay Adapter for relay Adapter for JFC Adapter for DTM Adapter for DT Adapter for DT Adapter for DT Adapter for DT Adapter for DT (Gray) Adapter for DT (Black) Adapter for DT (Green) Adapter for DT (Brown) Adapter for DT (Gray) Adapter for DT (Black) Adapter for DT (Green) Adapter for DT (Brown) Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-18 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Adapter for HD30-24 Plate for HD30 (24-pin) T-box (for ECONO) Case Case Adapter for DRC Adapter for DRC Socket for engine (CRI-T2) Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor Socket for engine (CRI-T2) 799-601-9430* Socket for engine(CRI-T3) PCV

8 10 12 16 16 12 8 12 16 20 2

S8P S10P S12P S16P S16PW S12PW A8P A12P A16P A20P

q q q q

q q q q

q q q q

q q q q q q q q

q q q q q q q q q q q q q q

10 12 14 18 20 5 6 2 2 2 3 4 6 8 8 8 8 12 12 12 12 8 14 20 21 9 16 21 23 31 24

07-10 07-12 07-14 07-18 07-20 REL-5P REL-6P DTM2 DT2 DT3 DT4 DT6 DT8GR DT8B DT8G DT8BR DT12GR DT12B DT12G DT12BR D18-8 D18-14 D18-20 D18-21 D24-9 D24-16 D24-21 D24-23 D24-31

q q q q q

q q q q q q q q q q q q q q q q q q q q q q q q q

q q q q q q q q q q q q

q q q q q q q q q q q q q

q q q q q q q

q q q q q q q q

40 24 2 3 2

DRC-40 DRC-24 G A3 P

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General information on troubleshooting T- branch box and T- branch adapter table

Number of pins

T-adapter kit 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 Identificati-on symbol Out of kit

Part No.

Part name

799-601-9440* Socket for engine (CRI-T2) 795-799-5520* Socket for engine (HPI-T2) Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2) 795-799-5540* Socket for engine(CRI-T3) TIM 795-799-5460 Cable for engine (HPI-T2) 795-799-5470 Cable for engine (HPI-T2) 795-799-5480 Cable for engine (HPI-T2) 799-601-4110 Adapter for engine (140-T3) PIM 799-601-4130 Adapter for engine (CRI-T3) NE, CAM Adapter for engine (CRI-T3) 799-601-4140 Ambient pressure 799-601-4150 Adapter for engine (CRI-T3) POIL Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch 799-601-4180 Adapter for engine (CRI-T3) PEVA Socket for engine (CRI-T3) 799-601-4190* Common rail pressure Socket for engine (CRI-T3) 799-601-4230* Air intake pressure/temperature 799-601-4240* Socket for engine (CRI-T3) PAMB 799-601-4250* Socket for engine (CRI-T3) PIM 799-601-4330* Socket for engine (CRI-T3) G Socket for engine (CRI-T3) 799-601-4340* Pump actuator Socket for engine (CRI-T3)(95) 799-601-4380* Air intake pressure/temperature 799 -601-4260 Adapter for controller (ENG) 799 -601-4211 Adapter for controller (ENG) 799-601-4220 Adapter for controller (ENG) 799-601-4390* Socket for controller (95 ENG) 799-601-4280* Box for controller (PUMP) 799-601-9720 Adapter for controller (HST) 799-601-9710 Adapter for controller (HST) 799-601-9730 Adapter for controller (HST) 799-601-9890 Multi-adapter for DT2 to 4 and DTM2

3 2 2 2 3 3 3 4 3 3 3 2 3 3 4 3 3 3 2 4 4 50 60 60 121 16 16 26 2, 3, 4

1, 2, 3 S C A ITT3N FCIN FCIG FCIB 4160 4180 1, 2, 3 L 1, 2, 3, 4 C 1, 2, 3 A 1, 2, 3 B 1, 2, 3, G 2, PA 1, 2, 3, 4T DTP4 DRC50 DRC60 HST16A HST16B HST26A

q q

q q q q q q q

q q q q q q q q q q q q q q q q q q q q q q q q

q q q q q

q q q q q q

* Shows not T-adapter but socket.

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General information on troubleshooting 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 power. 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 supplied regardless of the starting switch position, ON or OFF.
Type of power supply Circuit breaker No. 1 2 Switched power supply (battery relay M terminal) 3 4 5 6 Continuous power supply (battery relay B terminal) Switched power supply (battery relay M terminal) 7 8 9 10 11 Continuous power supply (battery relay B terminal) 12 13 14 Circuit breaker capacity 60 A 60 A 60 A 60 A 60 A 60 A 50 A 50 A 135 A 135 A 20 A 20 A 20 A 20 A Destination of power Fuse box III 4 to 7 Front working lamp (1) Fuse box III 1 to 3 Fuse box II 10 to 14 Horn Fuse box II 1 to 9 Work equipment pump solenoid Fuse box I 13 to 15 Fuse box I 10 to 12 Fuse box I 6 to 9 Fuse box I 1 to 5 Alternator power supply Alternator power supply Engine controller Engine controller Engine controller Engine controller

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General information on troubleshooting Table of fuse locations

40-108 Connection table of fuse 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.
q

Fuse box I Type of power supply Continuous power supply (circuit breaker No. 8)

Continuous power supply (circuit breaker No. 7) Continuous power supply (circuit breaker No. 6) Continuous power supply (circuit breaker No. 5) Fuse box II Type of power supply

Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Fuse capacity 20 A 10 A 5A 5A 10 A 10 A 10 A 20 A 10 A 20 A 20 A 20 A 10 A 30 A 20 A Fuse capacity 20 A 10 A 20 A 10 A 5A 5A 10 A 10 A 10 A 10 A 20 A 20 A 20 A 20 A

Destination of power Starting switch CAN power supply line Transmission controller (B) Work equipment controller (B) KOMTRAX Plus main monitor Hazard lamp Spare (continuous power supply) Step lamp Spare Air conditioner (A) Air conditioner (B) Air suspension seat, cigarette lighter Work equipment pump solenoid Spare Revolving warning lamp (if equipped) Destination of power Horn Turn signal lamp Buckup lamp and brake lamp Transmission controller (A) Parking brake pilot lamp Emergency parking brake Work equipment controller (A) KOMTRAX Plus controller Radio Auto-greasing pilot lamp Front wiper and washer Rear wiper and washer Power window L.H. Power window R.H.

Switched power supply (circuit breaker No. 5)

Switched power supply (circuit breaker No. 3)

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General information on troubleshooting Table of fuse locations

Fuse box III Type of power supply Switched power supply (circuit breaker No. 2) Fuse No. 1 2 3 4 5 6 Switched power supply (circuit breaker No. 1) 7 8 9 10 11 Continuous power supply (circuit breaker No. 11 to 14) Switched power supply (circuit breaker No. 7) 12 13 14 15 Fuse capacity Destination of power 20 A 20 A 10 A 30 A 20 A 10 A 10 A 10 A 10 A 10 A 10 A 5A 5A Front working lamp (1) Rear working lamp Front working lamp (2) Fog lamp, side working lamp Main lamp circuit Spare Spare Right clearance lamp Left clearance lamp Right headlamp Left headlamp Engine controller Auto greasing system level gauge (if equipped)

Location of fuse box and fuse number Fuse box I, II

Fuse No. I, II

Fuse box III

Fuse No. III

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General information on troubleshooting Table of fuse locations

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 power. 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 supplied regardless of the starting switch position, ON or OFF.
Type of power supply Circuit breaker No. 1 2 Switched power supply (battery relay M terminal) 3 4 5 6 Continuous power supply (battery relay B terminal) Switched power supply (battery relay M terminal) 7 8 9 10 11 Continuous power supply (battery relay B terminal) 12 13 14 Circuit breaker capacity 60 A 60 A 60 A 60 A 60 A 60 A 50 A 50 A 135 A 135 A 20 A 20 A 20 A 20 A Destination of power Fuse box III 4 to 7 Front working lamp (1) Fuse box III 1 to 3 Fuse box II 10 to 14 Horn Fuse box II 1 to 9 Work equipment pump solenoid Fuse box I 13 to 15 Fuse box I 10 to 12 Fuse box I 6 to 9 Fuse box I 1 to 5 Alternator power supply Alternator power supply Engine controller Engine controller Engine controller Engine controller

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General information on troubleshooting Table of fuse locations

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 Continuous power supply (circuit breaker No. 8) Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fuse No. 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Fuse capacity 20 A 10 A 5A 5A 10 A 10 A 10 A 20 A 10 A 20 A 20 A 20 A 10 A 30 A 20 A Fuse capacity 20 A 10 A 20 A 10 A 5A 5A 10 A 10 A 10 A 10 A 20 A 20 A 20 A 20 A Destination of power Starting switch CAN power supply line Transmission controller (B) Work equipment controller (B) KOMTRAX Plus main monitor Hazard lamp Spare (continuous power supply) Step lamp Spare Air conditioner (A) Air conditioner (B) Air suspension seat, cigarette lighter Work equipment pump solenoid Spare Revolving warning lamp (if equipped) Destination of power Horn Turn signal lamp Buckup lamp and brake lamp Transmission controller (A) Parking brake pilot lamp Emergency parking brake Work equipment controller (A) KOMTRAX Plus controller Radio Auto-greasing pilot lamp Front wiper and washer Rear wiper and washer Power window L.H. Power window R.H.

Continuous power supply (circuit breaker No. 7) Continuous power supply (circuit breaker No. 6) Continuous power supply (circuit breaker No. 5) Fuse box II Type of power supply

Switched power supply (circuit breaker No. 5)

Switched power supply (circuit breaker No. 3)

Fuse box III Type of power supply Switched power supply (circuit breaker No. 2) Fuse No. 31 32 33 34 35 36 Switched power supply (circuit breaker No. 1) 37 38 39 40 41 Continuous power supply (circuit breaker No. 11 to 14) Switched power supply (circuit breaker No. 7) 42 43 44 45 Fuse capacity Destination of power 20 A 20 A 10 A 30 A 20 A 10 A 10 A 10 A 10 A 10 A 10 A 5A 5A Front working lamp (1) Rear working lamp Front working lamp (2) Fog lamp, side working lamp Main lamp circuit Spare Spare Right clearance lamp Left clearance lamp Right headlamp Left headlamp Engine controller Auto greasing system level gauge (if equipped)

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General information on troubleshooting Table of fuse locations

Location of fuse box and fuse number Fuse box I, II

Fuse No. I

Fuse No. II

Fuse box III

Fuse No. III

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General information on troubleshooting Table of fuse locations

FOR AJSS SPECIFICATION MACHINE

Location and connection table for relay
Relay No. L118 L51 L69 L57 L58 L59 L60 L61 L52 L53 L54 L55 L104 L48 L45 L65 L106 L101 Relay name Front windshield washer Side working light SW pump pnc sol Neutral Turn (L) P/B safety Front working light Rear working light Hazzard Stop light Backup alarm Horn Turn signal lighthazzard Fog lamp Rear wiper Turn (R) (Beacon lamp) Side marker light Remarks Relay No. L56 L119 L71 L49 L117 L75 L120 L134 L127 L121 L135 L123 L132 L143 L122 L133 L160 Head light Side windshield washer Power window Stairway light Wiper changeover Working light Wiper relay low Dust indicator S/T neutral inter lock Wiper relay high Dust indicator Wiper interval RH Dust indicator Buzzer 2 Wiper interval LH Dust indicator Working system Relay name Remarks

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General information on troubleshooting Table of fuse locations

Location and connection table for air conditioner relay

Relay No. A05 A01 A06 A02 A07 A03 A08 A04 Blower Blower Magnetic clutch Blower Condenser LH Blower Condeser RH Condenser Relay name Remarks

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General information on troubleshooting Table of fuse locations

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40-109-6

Troubleshooting by failure code Failure code [1500L0] Double Engagement of Transmission Clutches

Troubleshooting by failure code

WA1200-6

Failure code [1500L0] Double Engagement of Transmission Clutches

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q

40-1 0

40-1 0

Failure code 1500L0

Failure

Detection of double engagements (Transmission controller system)

A fill signal is input for a combination of double engagements. Turns centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Transmission may be damaged. Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

q q

1 See failure codes "15SAL1", "15SBL1", "15SEL1", "15SFL1", and "15SGL1".

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Troubleshooting by failure code Failure code [1540N1] T/M overrun

Failure code [1540N1] T/M overrun

Action level E02 Detail of failure Action of controller Problem on machine Related information No.
q

40-1 1

Failure code 1540N1

Failure

T/M overrun alarm (Transmission controller)

When gear speed is in other than neutral, a transmission output shaft speed signal exceeding the limit specified to each gear speed for overrun prevention is detected. Turns the centralized warning lamp and alarm buzzer ON. Returns to normal condition when transmission output shaft speed becomes below 1418 rpm. Continuing to travel in this condition may lead to transmission damage. Information on transmission overrunning prevention command activation is obtained from transmission controller over the network. Cause
q

q q q q

Procedure, measuring location, criteria and remarks Engine is overrunning if machine is traveling as indicated by the transmission output shaft speed signal exceeding 1,527 rpm If machine is not traveling as indicated by the transmission output shaft speed signal exceeding 1,527 rpm, transmission controller is defective

1 Engine overrun 2 Defective transmission controller

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Troubleshooting by failure code Failure code [15B0NX] T/M Oil Filter Clogged

Failure code [15B0NX] T/M Oil Filter Clogged

Action level E01 Failure code 15B0NX Failure Clogging of transmission oil filter (Monitor panel controller system)

40-1 2

Detail of failure Transmission oil filter clogging is indicated Action of controller Problem on machine Related information No.
q

Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position.

Clogging warning output (false detection) a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor q This failure code is issued when the engine is running Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector R01 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Check if indication goes out when a jumper wire is connected between transmission oil filter sensor (R01) (female) (1) and (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector R02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Check if indication goes out when a jumper wire is connected between transmission oil filter sensor (R02) (female) (1) and (2) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to FC04 connector and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between FC04 (female) (5) and R01 Max. 1 z (female) (1) Wiring harness between FC03 (female) (5) and R02 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 1. Prepare with starting switch at OFF position. 2. Disconnect connector JR6 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between JR6 (male) (6), (8) and (1) Resistance Max. 1 z 1. Prepare with starting switch at OFF position. 2. Disconnect FC03 or FC04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting.

Clogged transmission oil filter, or 1 defective transmission oil filter sensor (R01)

Clogged transmission oil filter, or 2 defective transmission oil filter sensor (R02)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

4 Defective joint connector (JR6)

5 Defective monitor panel controller

FC03 Between (5) and ground

Oil filter Normal Clogged

Voltage Max 1 V 17 30 V

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Troubleshooting by failure code Failure code [15B0NX] T/M Oil Filter Clogged

Related circuit diagram

40-1 3

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40-113

Troubleshooting by failure code Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit

Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit

Action level E03 Detail of failure Action of controller Problem on machine Related information
q q q q

40-1 4

Failure code 15SAL1

Failure

Ground fault in E-POC fill switch F (Transmission controller system)

When the signal is not output to F (forward) ECMV solenoid, the signal is output from F (forward) ECMV fill switch, and the clutch is not released. Judges that the signal is output from F (forward) ECMV fill switch. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). F (forward) travel is enabled, but R (reverse) travel is disabled. The output state (current) to the F (forward) clutch ECMV solenoid can be checked with the monitoring function (Code: 31608, ECMV F DIR). The input state (ON/OFF) from the F (forward) fill switch can be checked with the monitoring function (Code: 40908, D-IN-25). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 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. Directional lever or T14 (male) directional selector Resistance switch Between (1) and ground F (Forward) Other than above Max. 1 z Min. 1 Mz

q q q q

No.

Defective F (forward) ECMV fill switch (Internal short circuit)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Resistance Min. 1 Mz (female) (27) to T14 (female) (1)

1. Prepare with starting switch at OFF position. 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. 3 Defective transmission controller Directional lever or L03 directional selector Voltage switch Between (27) and ground F (Forward) Other than above Max. 1 V 810 V

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Troubleshooting by failure code Failure code [15SAL1] ECMV (F) Fill Switch Short Circuit

Related circuit diagram

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40-115

Troubleshooting by failure code Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect

Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect

Action level E01 Detail of failure Action of controller Problem on machine Related information
q q q q

40-1 6

Failure code 15SALH

Failure

Open circuit or hot short circuit in E-POC fill switch F (Transmission controller system)

When the signal is not output to F (forward) ECMV solenoid, the signal is output from F (forward) ECMV fill switch, and the clutch is not released. Judges that the signal is output from F (forward) ECMV fill switch. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). F (forward) travel is enabled, but R (reverse) travel is disabled. The output state (current) to the F (forward) clutch ECMV solenoid can be checked with the monitoring function (Code: 31608, ECMV F DIR). The input state (ON/OFF) from the F (forward) fill switch can be checked with the monitoring function (Code: 40908, D-IN-25). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 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. Directional lever or T14 (male) directional selector Resistance switch Between (1) and ground F (Forward) Other than above Max. 1 z Min. 1 Mz

q q q q

No.

Defective F (forward) ECMV fill switch (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconnected in turn. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L03 Voltage Max. 1 V (female) (27) to T14 (female) (1) 1. Prepare with starting switch at OFF position. 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. Directional lever or 3 Defective transmission controller L03 directional selector Voltage switch Between (27) and ground F (Forward) Other than above Max. 1 V 810 V

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Troubleshooting by failure code Failure code [15SALH] ECMV (F) Fill Switch circuit Disconnect

Related circuit diagram

40-1 7

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40-117

Troubleshooting by failure code Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit

Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit

Action level E03 Detail of failure Action of controller Problem on machine Related information
q q q q

40-1 8

Failure code 15SBL1

Failure

Ground fault in E-POC fill switch R (Transmission controller system)

When the signal is not output to R (reverse) ECMV solenoid, the signal is output from R (reverse) ECMV fill switch, and the clutch is not released. Judges that the R (reverse) ECMV fill switch signal is ON. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional selector switch is set to N (NEUTRAL). The machine can travel in reverse, but cannot travel forward. Output condition (current) to R (reverse) clutch ECMV solenoid can be checked with monitoring function (Code: 31606, ECMV R DIR). Input condition (ON/OFF) from the R (reverse) fill switch can be checked with monitoring function (Code: 40908 D-IN-26). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T12 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. Directional lever or T12 (made) directional selector Resistance switch Between (1) and ground R (forward) Other than above Max. 1 z Min. 1 Mz

q q q q

No.

Defective R (reverse) ECMV fill switch (internal short circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconnected in turn. Ground fault in wiring harness 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) (17) to T12 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector T12 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. Directional lever or 3 Defective transmission controller L03 directional selector Voltage switch Between (17) and ground R (forward) Other than above Max. 1 V 810 V

40-118

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Troubleshooting by failure code Failure code [15SBL1] ECMV (R) Fill Switch Short Circuit

Related circuit diagram

40-1 9

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40-119

Troubleshooting by failure code Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect

Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect

Action level E01 Detail of failure Action of controller Problem on machine Related information
q q q q

40-120

Failure code 15SBLH

Failure

Open circuit or hot short circuit in E-POC fill switch R (Transmission controller system)

When the signal is not output to R (reverse) ECMV solenoid, the signal is output from R (reverse) ECMV fill switch, and the clutch is not released. Judges that the R (reverse) ECMV fill switch signal is ON. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional selector switch is set to N (NEUTRAL). The machine can travel in reverse, but cannot travel forward. Output condition (current) to R (reverse) clutch ECMV solenoid can be checked with monitoring function (Code: 31606, ECMV R DIR). Input condition (ON/OFF) from the R (reverse) fill switch can be checked with monitoring function (Code: 40908 D-IN-26). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T12 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. Directional lever or T12 (made) directional selector Resistance switch Between (1) and ground R (forward) Other than above Max. 1 z Min. 1 Mz

q q q q

No.

Defective R (reverse) ECMV fill switch (internal short circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconnected in turn. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L03 Voltage Max. 1 V (female) (17) to T12 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector T12 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. Directional lever or 3 Defective transmission controller L03 directional selector Voltage switch Between (17) and ground R (forward) Other than above Max. 1 V 810 V

40-120

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Troubleshooting by failure code Failure code [15SBLH] ECMV (R) Fill Switch circuit Disconnect

Related circuit diagram

40-121

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40-121

Troubleshooting by failure code Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit

Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit

Action level E03 Detail of failure
q q

40-12

Failure code 15SEL1

Failure

Ground fault in E-POC fill switch 1 (Transmission controller system)

When 1st ECMV solenoid output is de-energized, 1st ECMV fill switch signal ON is input, and clutch is not released. Judges that the 1st ECMV fill switch signal is ON. Holds 2nd and 3rd proportional solenoid outputs OFF. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). The machine can travel in 1st, but not in 2nd or 3rd. The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function (Code: 31602, ECMV 1 DIR). The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code: 40908, D-IN-27). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T4 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. T4 (male) Between (1) and ground Gearshift lever 1st Other than above Resistance Max. 1 z Min. 1 Mz

Action of controller Problem on machine Related information

q q q

q q q q

No.

Defective 1st ECMV fill switch (internal short circuit)

Ground fault in wiring harness (contact with ground circuit)

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Resistance Min. 1 Mz (female) (7) to T4 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 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. q Set the auto shift and manual shift selector switch to MANUAL. q Set the directional lever to F or R position. L03 Between (7) and ground Gearshift lever 1st Other than above Voltage Max. 1 V 810 V

40-122

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Troubleshooting by failure code Failure code [15SEL1] ECMV (1) Fill Switch Short Circuit

Related circuit diagram

40-123

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40-123

Troubleshooting by failure code Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect

Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect

Action level E01 Detail of failure
q q

40-124

Failure code 15SELH

Failure

Open circuit or hot short circuit in E-POC fill switch 1 (Transmission controller system)

When 1st ECMV solenoid output is de-energized, 1st ECMV fill switch signal ON is input, and clutch is not released. Judges that the 1st ECMV fill switch signal is ON. Holds 2nd and 3rd proportional solenoid outputs OFF. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). The machine can travel in 1st, but not in 2nd or 3rd. The output state (current) to the 1st clutch ECMV solenoid can be checked with the monitoring function (Code: 31602, ECMV 1 DIR). The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code: 40908, D-IN-27). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T4 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. T4 (male) Between (1) and ground Gearshift lever 1st Other than above Resistance Max. 1 z Min. 1 Mz

Action of controller Problem on machine Related information

q q q

q q q q

No.

Defective 1st ECMV fill switch (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconHot short circuit in wiring harness nected in turn. 2 (contact with 24 V circuit) 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L03 Voltage Max. 1 V (female) (7) to T4 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 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. q Set the auto shift and manual shift selector switch to MANUAL. 3 Defective transmission controller q Set the directional lever to F or R position. Gearshift lever L03 Voltage Between (7) and ground 1st Other than above Max. 1 V 810 V

40-124

WA1200-6

Troubleshooting by failure code Failure code [15SELH] ECMV (1) Fill Switch circuit Disconnect

Related circuit diagram

40-125

WA1200-6

40-125

Troubleshooting by failure code Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit

Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit

Action level E03 Detail of failure
q q

40-126

Failure code 15SFL1

Failure

Ground fault in E-POC fill switch 2 (Transmission controller system)

When 2nd ECMV solenoid output is de-energized, 2nd ECMV fill switch signal ON is input, and clutch is not released. Turns the centralized warning lamp and alarm buzzer ON. Judges that the 2nd ECMV fill switch signal is ON. Holds 1st and 3rd proportional solenoid outputs OFF. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). The machine may be able to travel in 2nd, but not in 1st or 3rd. The output (current value) to the 2nd clutch ECMV solenoid can be checked with the monitoring function (Code: 31603, ECMV 2 DIR). The input condition (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code: 40908, D-IN-28). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch AT OFF position. 2. Disconnect connector T6 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. T6 (male) Between (1) and ground Gearshift lever 2nd speed Other than above Resistance Max. 1 z Min. 1 Mz

Action of controller Problem on machine Related information

q q q

q q q q

No.

Defective 2nd ECMV fill switch (internal short circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconnected in turn. Ground fault in wiring harness 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) (13) to T6 (female) (1) 1. Prepare with starting switch At OFF position. 2. Disconnect connector L03 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. 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 Between (13) and ground Gearshift lever 2nd speed Other than above Voltage Max. 1 V 810 V

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WA1200-6

Troubleshooting by failure code Failure code [15SFL1] ECMV (2) Fill Switch Short Circuit

Related circuit diagram

40-127

WA1200-6

40-127

Troubleshooting by failure code Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect

Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect

Action level E01 Detail of failure
q q

40-128

Failure code 15SFLH

Failure

Open circuit or hot short circuit in E-POC fill switch 2 (Transmission controller system)

When 2nd ECMV solenoid output is de-energized, 2nd ECMV fill switch signal ON is input, and clutch is not released. Turns the centralized warning lamp and alarm buzzer ON. Judges that the 2nd ECMV fill switch signal is ON. Holds 1st and 3rd proportional solenoid outputs OFF. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). The machine may be able to travel in 2nd, but not in 1st or 3rd. The output (current value) to the 2nd clutch ECMV solenoid can be checked with the monitoring function (Code: 31603, ECMV 2 DIR). The input condition (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code: 40908, D-IN-28). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T06 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. T6 (male) Between (1) and ground Gearshift lever 2nd speed Other than above Resistance Max. 1 z Min. 1 Mz

Action of controller Problem on machine Related information

q q q

q q q q

No.

Defective 2nd ECMV fill switch (internal disconnection)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconnected in turn. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L03 Voltage Max. 1 V (female) (13) to T6 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 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. 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 Between (13) and ground Gearshift lever 2nd speed Other than above Voltage Max. 1 V 810 V

40-128

WA1200-6

Troubleshooting by failure code Failure code [15SFLH] ECMV (2) Fill Switch circuit Disconnect

Related circuit diagram

40-129

WA1200-6

40-129

Troubleshooting by failure code Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit

Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit

Action level E03 Detail of failure
q q

40-130

Failure code 15SGL1

Failure

Ground fault in E-POC fill switch 3 (Transmission controller system)

When 3rd ECMV solenoid output is de-energized, 3rd ECMV fill switch signal ON is input, and clutch is not released. Judges that the 3rd ECMV fill switch signal is ON. Holds 1st and 2nd proportional solenoid outputs OFF. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional selector switch is set to N (NEUTRAL). The machine may be able to travel in 3rd, but not in 1st or 2nd. The output (current value) to the 3rd clutch ECMV solenoid can be checked with the monitoring function (Code: 31604, ECMV 3 DIR). The input condition (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code: 40908, D-IN-29). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T8 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. T8 (male) Between (1) and ground Gearshift lever 3rd Other than above Resistance Max. 1 z Min. 1 Mz

Action of controller Problem on machine Related information

q q q

q q q q

No.

Defective 3rd ECMV fill switch (internal short circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconGround fault in wiring harness nected in turn. 2 (contact with ground circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Resistance Min. 1 Mz (female) (3) to T8 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 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. 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 Between (3) and ground Gearshift lever 3rd Other than above Voltage Max. 1 V 810 V

40-130

WA1200-6

Troubleshooting by failure code Failure code [15SGL1] ECMV (3) Fill Switch Short Circuit

Related circuit diagram

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40-131

Troubleshooting by failure code Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect

Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect

Action level E01 Detail of failure
q q

40-132

Failure code 15SGLH

Failure

Open circuit or hot short circuit in E-POC fill switch 3 (Transmission controller system)

When 3rd ECMV solenoid output is de-energized, 3rd ECMV fill switch signal ON is input, and clutch is not released. Judges that the 3rd ECMV fill switch signal is ON. Holds 1st and 2nd proportional solenoid outputs OFF. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until directional selector switch is set to N (NEUTRAL). The machine may be able to travel in 3rd, but not in 1st or 2nd. The output (current value) to the 3rd clutch ECMV solenoid can be checked with the monitoring function (Code: 31604, ECMV 3 DIR). The input condition (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code: 40908, D-IN-29). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T8 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. T8 (male) Between (1) and ground Gearshift lever 3rd Other than above Resistance Max. 1 z Min. 1 Mz

Action of controller Problem on machine Related information

q q q

q q q q

No.

Defective 3rd ECMV fill switch (internal open circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to L03 connector and each connector to be disconHot short circuit in wiring harness nected in turn. 2 (contact with 24 V circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Voltage Max. 1 V (female) (3) to T8 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 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. 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 Between (3) and ground Gearshift lever 3rd Other than above Voltage Max. 1 V 810 V

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WA1200-6

Troubleshooting by failure code Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect

Related circuit diagram

40-13

WA1200-6

40-133

Troubleshooting by failure code Failure code [15SGLH] ECMV (3) Fill Switch circuit Disconnect

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Troubleshooting by failure code Failure code [2F00MA] Parking brake circuit failure

Failure code [2F00MA] Parking brake circuit failure

Action level E03 Detail of failure Action of controller Problem on machine Related information
q

40-135

Failure code 2F00MA

Failure

Open circuit in parking brake signal line (Machine monitor system)

When the F or R clutch is engaged, there is open circuit in the parking brake operation sensor circuit. (The neutralizer does not work.) Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. Parking brake drags (kept operated) Input condition (ON/OFF) from the parking indicator switch can be checked with monitoring function (Code: 40903 DIN-26). Engine may stall during travel or emergency brake activation may issue this error Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T18 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T18 (male) Between (1) and (2) Parking brake pilot lamp Released Operation Resistance Max. 1 z Min. 1 Mz

q q q q q q

No.

Defective parking brake indicator 1 switch (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connector FC09 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Parking brake pilot lamp FC09 (female) Resistance Switch 2 Defective parking brake indicator switch(Internal disconnection) Between (3) and (4) ON OFF ON OFF Ladder at any position Min. 1 Mz Max. 1 z Max. 1 z Min. 1 Mz Min. 1 Mz

Between (5) and (6) Between(3) and (6)

Defective parking brake solenoid (Internal disconnection)

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR14 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR14 (male) Between (1) and (2) Between (1), (2) and ground Resistance 10 to 40 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors HR17, HR18 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR17 (male), HR18 Parking brake pilot lamp Resistance (male) Normal brake oil presDefective emergency brake pres4 sure sure switch (internal open circuit) Max. 1 z Min. 4.9 MPa 2} {Min. 50 kg/cm Between (1) and (2) Low brake oil pressure Min. 3.14 MPa Min. 1 Mz {Max. 32 kg/cm2}

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Troubleshooting by failure code Failure code [2F00MA] Parking brake circuit failure

No.

Cause

Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC04, FC09, FC17, FC18 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between FC04 (female) (1) and Max. 1 z T18W (female) (1) Wiring harness between FC09 (female) (3) and Max. 1 z HR17 (female) (1) Open circuit in wiring harness 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 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC04 and connect T-adapter. 3. Start engine and perform troubleshooting Parking brake oil pres6 Defective machine monitor FC04 Voltage sure Between (1) and ground Released Operation Max. 1 V Max. 1 V

40-136

WA1200-6

Troubleshooting by failure code Failure code [2F00MA] Parking brake circuit failure

Related circuit diagram

40-137

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40-137

Troubleshooting by failure code Failure code [2G42ZG] Accumulator Oil Press. F Low

Failure code [2G42ZG] Accumulator Oil Press. F Low

Action level E03 Failure code 2G42ZG Failure Front brake pressure too low (when in operation) (KOMTRAX Plus controller system)

40-138

Detail of failure Front brake oil pressure drop is indicated while machine is operating Action of controller Problem on machine
q q

Turns the centralized warning lamp and alarm buzzer ON.

Real-time monitor display: constantly detects minimum pressure below (0 MPa {0 kg/cm2}) q Alarm false detected a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Related inforq This failure code is displayed when the brake cut-out pressure becomes lower than 14.71 MPa mation {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 No. Cause Procedure, measuring location, criteria and remarks

Front brake pressure too low or 1 defective front brake oil pressure sensor

1. Prepare with starting switch at OFF position. 2. Start engine and perform troubleshooting. Check if "2G42ZG" is displayed when sensor is replaced with the rear brake oil pressure sensor (normally operating) 1. Prepare with starting switch at OFF position. 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) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to V2A connector and each connector to be disconnected 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) 1. Prepare with starting switch at OFF position. 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

Troubleshooting by failure code Failure code [2G42ZG] Accumulator Oil Press. F Low

Related circuit diagram

40-139

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40-139

Troubleshooting by failure code Failure code [2G43ZG] Accumulator Oil Press. R Low

Failure code [2G43ZG] Accumulator Oil Press. R Low

Action level E03 Failure code 2G43ZG Failure Rear brake pressure too low (when in operation) (KOMTRAX Plus controller system)

40-140

Detail of failure Rear brake oil pressure drop is indicated while machine is operating Action of controller Problem on machine
q q

Turns the centralized warning lamp and alarm buzzer ON.

Real-time monitor display: constantly detects minimum pressure below (0 MPa {0 kg/cm2}) q Alarm false detected a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Related inforq This failure code is displayed when the brake cut-out pressure becomes lower than 14.71 MPa mation {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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Start engine and perform troubleshooting.

Rear brake pressure too low or 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) 1. Prepare with starting switch at OFF position. 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) (8) and Max. 1 z HR16 (female) (C) Resistance Wiring harness between JR14 (female) (6) and Max. 1 z HR16 (female) (B) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to V2A connector and each connector to be disconnected 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 (female) (8) to HR16 (female) (C) Resistance Between ground and wiring harness from JR14 Min. 1 Mz (female) (6) to HR16 (female) (B) 1. Prepare with starting switch at OFF position. 2. Disconnect connector V2A and connect T-adapter. 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

Troubleshooting by failure code Failure code [2G43ZG] Accumulator Oil Press. R Low

Related circuit diagram

40-141

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40-141

Troubleshooting by failure code Failure code [44K0L4] Bucket cylinder position detector SW failure

Failure code [44K0L4] Bucket cylinder position detector SW failure

Action level E01 Failure code 44K0L4 Failure Bucket cylinder horizontal proximity switch system error (input signal out of range) (Boom bucket & AJSS controller system)

40-142

Detail of failure Open circuit has occurred in bucket cylinder horizontal proximity switch circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect F13 sensor, replace it with a normally operating relay, and connect T-adapter. 1 Defective bucket positioner leveler 3. Turn starting switch to ON position and perform troubleshooting. Replace with a normally operating Failure code disappears proximity switch 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, F13 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness Wiring harness between L07 (female) (20) and F13 Max. 1 z 2 (wire breakage or defective con- (female) (B) 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. Between ground and wiring harness from L07 Ground fault in wiring harness Min. 1 Mz 3 (female) (20) to F13 (female) (B) (contact with ground circuit) Resistance Between ground and wiring harness from L07 Min. 1 Mz (female) (22) to F13 (female) (A) a Be ready with starting switch OFF, then turn starting switch to ON position and perform troubleshooting. L07 (female) Between (20), (22) and ground Resistance Min. 1 Mz

Defective boom bucket & AJSS controller

Related circuit diagram

40-142

40-142

WA1200-6

Troubleshooting by failure code Failure code [7REAKA] ACC Signal Malfunction

Failure code [7REAKA] ACC Signal Malfunction

Action level E01 Failure code 7REAKA Failure ACC signal system error (input signal out of range) (KOMTRAX Plus controller system)

40-143

Detail of failure Open circuit has occurred in ACC signal circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1, L04, L07 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (17) and L04 Max. 1 z (female) (14), (24) Resistance Wiring harness between V1 (female) (17) and L07 Max. 1 z (female) (14), (24)
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Related electrical circuit diagram

40-143

WA1200-6

40-143

Troubleshooting by failure code Failure code [989P00] Direction protection warning

Failure code [989P00] Direction protection warning

Action level Detail of failure Action of controller Problem on machine Related information No.
q q

40-14

Failure code 989P00

Failure

Direction protect alarm: alarm activated (KOMTRAX Plus controller system)

F/R changed at improper travel speed

The failure code is recorded to KOMTRAX Plus controller.

Cause

Procedure, measuring location, criteria and remarks Change F/R at proper travel speed (Instruct the operator on correct operation of the machine.)

1 Incorrect operation

Failure code [989Q00] Work equipment protection

Action level Detail of failure
q q

40-14

Failure code 989Q00

Failure

Wall surface digging prevention alarm: alarm activated (KOMTRAX Plus controller system)

Attempt to apply a load exceeding the safe level to the work equipment by digging a wall surface. Alarm conditions Multi monitor (option settings): ON At TILT end Hinge pin height above 1.35 m Travel speed: below 1 km/h Driving force: above 45 tons Level ground: (max. 3 deg.), uphill (min. 4 deg.) 2 sec. after switching F/R

1. 2. Action of con- 3. troller 4. 5. 6. 7. Problem on machine Related inforq mation No.

Lets modulation clutch slip to lower driving force and protect work equipment Procedure, measuring location, criteria and remarks (Instruct the operator on correct operation of the machine.)

Cause

1 Incorrect operation

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Troubleshooting by failure code Failure code [989R00] Tire slip

Failure code [989R00] Tire slip

Action level Detail of failure
q

40-145
Tire slip prevention control operation (Machine monitor system)

Failure code 989R00 Tire slip has occurred

Failure

q Alarm conditions 1. Travel speed: above 60 km/h Difference in speed between right and left tires: above 4.0 km/h 2. Driving force: above 56 tons Travel speed: 1.54.5 km/h Action of conDifference in speed between right and left tires: above 2.75 km/h troller 3. Driving force: above 56 tons Travel speed: 1.54.5 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 information No.

Decreases modulation clutch pressure to lower driving force and prevent slip Cause Procedure, measuring location, criteria and remarks (Instruct the operator on correct operation of the machine.)

1 Incorrect operation

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40-145

Troubleshooting by failure code Failure code [989S00] Parking Brake Dragging

Failure code [989S00] Parking Brake Dragging

Action level Failure code 989S00 Failure Parking brake system error (input signal out of range) (Transmission controller system)

40-146

Detail of failure Open circuit has occurred in parking brake sensor circuit. Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, HR14, LS6 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (6) and HR14 Max. 1 z (female) (1) Wiring harness between L03 (female) (16) and LS6 Max. 1 z (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) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, HR14, LS6 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Min. 1 Mz (female) (6) to HR14 (female) (1) Between ground and wiring harness from L03 Min. 1 Mz (female) (16) to LS6 (female) (4) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (26) to LS6 (female) (3) Between ground and wiring harness from L03 (female) (36) to LS6 (female) (2) Min. 1 Mz
q

The failure code is recorded to KOMTRAX Plus controller.

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L03(female) Between (6), (16), (26), (36) and ground Resistance Min. 1 Mz

40-146

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Troubleshooting by failure code Failure code [989S00] Parking Brake Dragging

Related circuit diagram

40-147

WA1200-6

40-147

Troubleshooting by failure code Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF)

Failure code [989T00] Stationary steering (Brake: OFF, Load: OFF)

Action level Detail of failure
q q

40-148

Failure code 989T00

Failure

Stationary steering detection alarm: alarm activated (KOMTRAX Plus controller)

Stationary steering has been attempted Stationary steering detection conditions Travel speed: below 1 km/h Brakes: OFF Steering (frame angle deflection): Min. 10 deg/sec Steering: Min. 10 deg./sec No load (decided by boom bottom pressure and boom angle) The failure code is recorded to KOMTRAX Plus controller.

Action of controller

Problem on machine Related information No.

Cause

Procedure, measuring location, criteria and remarks (Instruct the operator on correct operation of the machine.)

1 Incorrect operation

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Troubleshooting by failure code Failure code [989U00] Stationary steering (Brake: OFF, Load: ON)

Failure code [989U00] Stationary steering (Brake: OFF, Load: ON)

Action level Detail of failure Action of controller Problem on machine Related information No.
q q

40-149

Failure code 989U00

Failure

Stationary steering detection alarm: alarm activated (KOMTRAX Plus controller)

Stationary steering has been attempted Stationary steering detection conditions Travel speed: below 1 km/h Brakes: OFF Steering (frame angle deflection): Min. 10 deg/sec Loaded (decided by boom bottom pressure and boom angle) The failure code is recorded to KOMTRAX Plus controller.

Cause

Procedure, measuring location, criteria and remarks (Instruct the operator on correct operation of the machine.)

1 Incorrect operation

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40-149

Troubleshooting by failure code Failure code [989V00] Stationary steering (Brake: ON, Load: OFF)

Failure code [989V00] Stationary steering (Brake: ON, Load: OFF)

Action level Detail of failure Action of controller Problem on machine Related information No.
q q

40-150

Failure code 989U00

Failure

Stationary steering detection alarm: alarm activated (KOMTRAX Plus controller)

Stationary steering has been attempted Stationary steering detection conditions Travel speed: below 1 km/h Brakes: ON Steering (frame angle deflection): Min. 10 deg/sec No load (decided by boom bottom pressure and boom angle) The failure code is recorded to KOMTRAX Plus controller.

Cause

Procedure, measuring location, criteria and remarks (Instruct the operator on correct operation of the machine.)

1 Incorrect operation

40-150

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Troubleshooting by failure code Failure code [989W00] Stationary steering (Brake: ON, Load: ON)

Failure code [989W00] Stationary steering (Brake: ON, Load: ON)

Action level Detail of failure Action of controller Problem on machine Related information No.
q q

40-151

Failure code 989W00

Failure

Stationary steering detection alarm: alarm activated (KOMTRAX Plus controller)

Stationary steering has been attempted Stationary steering detection conditions Travel speed: below 1 km/h Brakes: ON Steering (frame angle deflection): Min. 10 deg/sec Loaded (decided by boom bottom pressure and boom angle) The failure code is recorded to KOMTRAX Plus controller.

Cause

Procedure, measuring location, criteria and remarks (Instruct the operator on correct operation of the machine.)

1 Incorrect operation

WA1200-6

40-151

Troubleshooting by failure code Failure code [AA1ANX] Air Cleaner 1 Clogging

Failure code [AA1ANX] Air Cleaner 1 Clogging

WA1200-6

40-152

Action level E01

Failure code AA1ANX

Failure

Clogging of air cleaner 1 (Monitor panel controller system)

Detail of failure Clogging of air cleaner 1 is indicated Action of controller

q

Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Wrong alarm output machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if indication goes out when connector (B06) of the dust indicator [1] is disconnected. 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. 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 female side. Wiring harness between FC03 (female) (2) and Max. 1 z L132 (female) (6) Resistance Wiring harness between L132 (female) (3) and Max. 1 z ground 1. Turn starting switch to OFF position. 2. Disconnect connectors FC03, B06, L132, and connect T-adapters to each female side. Between ground and wiring harness from B06 Resistance Min. 1 Mz (female) (1) to L132 (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect FC03 and connect T-adapter. 3. Turn starting switch to ON position. FC03 Between (2) and ground Air cleaner Normal Clogged Voltage Max 1 V 17 30 V

1 Defective dust indicator [1]

Defective dust indicator relay [1] (L132)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

5 Defective monitor panel controller

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Troubleshooting by failure code Failure code [AA1ANX] Air Cleaner 1 Clogging

Related circuit diagram

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40-153

Troubleshooting by failure code Failure code [AA1BNX] Air Cleaner 2 Clogging

Failure code [AA1BNX] Air Cleaner 2 Clogging

Action level E01 Failure code AA1BNX Failure Clogging of air cleaner 2 (Monitor panel controller system)

40-154

Detail of failure Clogging of air cleaner 2 is indicated Action of controller

q

Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Wrong alarm output machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if indication goes out when connector (B07) of the dust indicator [2] is disconnected. 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if display goes out when dust indicator relay [2] (L133) is replaced with another relay 1. Turn starting switch to OFF position. 2. Disconnect connectors FC03, B07, L133, and connect T-adapters to each female side. Wiring harness between FC03 (female) (3) and Max. 1 z L133 (female) (6) Resistance Wiring harness between L133 (female) (3) and Max. 1 z ground 1. Turn starting switch to OFF position. 2. Disconnect connectors FC03, B07, L133, and connect T-adapters to each female side. Between ground and wiring harness from B07 Resistance Min. 1 Mz (female) (1) to L133 (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect FC03 and connect T-adapter. 3. Turn starting switch to ON position. FC03 Between (3) and ground Air cleaner Normal Clogged Voltage Max 1 V 17 30 V

1 Defective dust indicator [2]

Defective dust indicator relay [2] (L133)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

5 Defective monitor panel controller

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Troubleshooting by failure code Failure code [AA1BNX] Air Cleaner 2 Clogging

Related circuit diagram

40-15

WA1200-6

40-155

Troubleshooting by failure code Failure code [AA1CNX] Air Cleaner 3 Clogging

Failure code [AA1CNX] Air Cleaner 3 Clogging

Action level E01 Failure code AA1CNX Failure Clogging of air cleaner 3 (Monitor panel controller system)

40-156

Detail of failure Clogging of air cleaner 3 is indicated Action of controller

q

Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Wrong alarm output machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if indication goes out when connector (B08) of the dust indicator [3] is disconnected. 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if display goes out when dust indicator relay [3] (L134) is replaced with another relay 1. Turn starting switch to OFF position. 2. Disconnect connectors FC03, B08, L134, and connect T-adapters to each female side. Wiring harness between FC03 (female) (8) and Max. 1 z L134 (female) (6) Resistance Wiring harness between L134 (female) (3) and Max. 1 z ground 1. Turn starting switch to OFF position. 2. Disconnect connectors FC03, B08, L134, and connect T-adapters to each female side. Between ground and wiring harness from B08 Resistance Min. 1 Mz (female) (1) to L134 (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect FC03 and connect T-adapter. 3. Turn starting switch to ON position. FC03 Between (8) and ground Air cleaner Normal Clogged Voltage Max 1 V 17 30 V

1 Defective dust indicator [3]

Defective dust indicator relay [3] (L134)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

5 Defective monitor panel controller

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Troubleshooting by failure code Failure code [AA1CNX] Air Cleaner 3 Clogging

Related circuit diagram

40-157

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Troubleshooting by failure code Failure code [AA1DNX] Air Cleaner 4 Clogging

Failure code [AA1DNX] Air Cleaner 4 Clogging

Action level E01 Failure code AA1DNX Failure Clogging of air cleaner 4 (Monitor panel controller system)

40-158

Detail of failure Clogging of air cleaner 4 is indicated Action of controller

q

Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Wrong alarm output machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if indication goes out when connector (B09) of the dust indicator [4] is disconnected. 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if display goes out when dust indicator relay [4] (L135) is replaced with another relay 1. Turn starting switch to OFF position. 2. Disconnect connectors FC03, B09, L135, and connect T-adapters to each female side. Wiring harness between FC03 (female) (9) and Max. 1 z L135 (female) (6) Resistance Wiring harness between L135 (female) (3) and Max. 1 z ground 1. Turn starting switch to OFF position. 2. Disconnect connectors FC03, B09, L135, and connect T-adapters to each female side. Between ground and wiring harness from B09 Resistance Min. 1 Mz (female) (1) to L135 (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect FC03 and connect T-adapter. 3. Turn starting switch to ON position. FC03 Between (9) and ground Air cleaner Normal Clogged Voltage Max 1 V 17 30 V

1 Defective dust indicator [4]

Defective dust indicator relay [4] (L135)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

5 Defective monitor panel controller

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Troubleshooting by failure code Failure code [AA1DNX] Air Cleaner 4 Clogging

Related circuit diagram

40-159

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40-159

Troubleshooting by failure code Failure code [AB00L6] Discharge of alternator R terminal

Failure code [AB00L6] Discharge of alternator R terminal

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q

40-160

Failure code AB00L6

Failure

Hot short circuit in alternator R (Monitor panel system)

When engine is stopped, alternator terminal R input voltage is 12 V or above. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. Engine does not start Service meter reading advances by only turning starting switch to ON position. The input (voltage) from the alternator can be checked by using the monitoring function (Code: 04302, ALTERNATOR R). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector E04 and connect T-adapter. 3. Start engine and perform troubleshooting.

Defective alternator (internal defect)

Alternator Between terminal R (E03) and ground

Engine Start (throttle opened 1/2 or more) Stopped

Voltage 27.5 to 29.5 V Max. 1 V

1. Prepare with starting switch at OFF position. 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 (contact with 24 V circuit) Wiring harness between alternator terminal R (E03) and FC02 (female) (18), V24 (female) (4), Voltage Max. 1 V and circuit branch 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC02 and connect T-adapter. 3. Start engine and perform troubleshooting. 3 Defective monitor panel FC02 Engine Start (throttle opened 1/2 or more) Stopped Voltage 27.5 to 29.5 V Max. 1 V

Between (18) and ground

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Troubleshooting by failure code Failure code [AB00L6] Discharge of alternator R terminal

Related circuit diagram

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Troubleshooting by failure code Failure code [AB00MA] Discharge of alternator R terminal

Failure code [AB00MA] Discharge of alternator R terminal

Action level E03 Failure code AB00MA Failure Ground fault, open circuit, or low charge voltage in alternator R (Monitor panel controller system)

40-162

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 conq Turns the centralized warning lamp and alarm buzzer ON. troller Problem on machine
q q q

Lowe battery charge level A similar error is detected by KOMTRAX Plus controller as [AB00MB] Controller 4 pin monitors the charging voltage from the alternator (R terminal) Charging voltage from alternator (R terminal) is normal: Min. 12 V Charging voltage from alternator (R terminal) is not normal: Hysteresis of Max. 5 V Alternator R terminal voltage input to the monitor panel controller can be checked with monitoring code: 04302 (V) Cause Procedure, measuring location, criteria and remarks 1) Turn starting switch ON. 2) Start the engine and perform troubleshooting. Between connector E04 (5) and ground Voltage Min. 12 V 1) Turn starting switch to OFF position. 2) Disconnect connector E04. 3) Disconnect connector FC02, then perform troubleshooting with the connector remaining disconnected. Between E04 (female) (5) and FC02 (female) (18) Resistance Max. 1 z 1) Turn starting switch to OFF position. 2) Disconnect connector E04. 3) Disconnect connector FC02, then perform troubleshooting with the connector remaining disconnected. Between FC02 (female) (18) and ground Resistance Min. 1 Mz

Related information
q

No.

1 Defective alternator

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

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 performed.)

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Troubleshooting by failure code Failure code [AB00MA] Discharge of alternator R terminal

Related circuit diagram

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Troubleshooting by failure code Failure code [AB00MB] Discharge of alternator R terminal

Failure code [AB00MB] Discharge of alternator R terminal

Action level E03
q

40-164

Failure code AB00MB

Failure

Ground fault, open circuit, or low charge voltage in alternator R (KOMTRAX Plus controller system)

Detail of failure Action of controller Problem on machine

q q q q

Engine is not operated normally (500 rpm or more), due to the CAN communication data with the engine controller. However, the system is judged that charging voltage (R or less) from the alternator 5 V terminal is present. Detail of failure is displayed in yellow on the multi-monitor screen.

Related information

This failure code is not displayed if CAN communication from engine controller is not possible. A similar error is detected by monitor panel controller as [AB00MA]. Controller 4 pin monitors the charging voltage from the alternator (R terminal) Charging voltage from alternator (R terminal) is normal: Min. 12 V Charging voltage from alternator (R terminal) is not normal: Hysteresis of Max. 5 V Alternator R terminal voltage input to the monitor panel controller can be checked with monitoring code: 04302 (V) Cause Procedure, measuring location, criteria and remarks 1) Turn starting switch ON. 2) Start the engine and perform troubleshooting. Between connector E04 (5) and ground Voltage Min. 12 V 1) Turn starting switch to OFF position. 2) Disconnect connector E04. 3) Disconnect connector V2A, then perform troubleshooting with the connector remaining disconnected. Between E04 (female) (5) and V2A (female) (4) Resistance Max. 1 z 1) Turn starting switch to OFF position. 2) Disconnect connector E04. 3) Disconnect connector V2A, then perform troubleshooting with the connector remaining disconnected. Between V2A (female) (4) and ground Resistance Min. 1 Mz

No.

1 Defective alternator

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

If no failure is found in checks on causes 1 to 3, KOMTRAX Plus controller may Defective KOMTRAX Plus control4 be defective. (Since this is an internal defect, troubleshooting cannot be perler formed.)

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Troubleshooting by failure code Failure code [AB00MB] Discharge of alternator R terminal

Related circuit diagram

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40-165

Troubleshooting by failure code Failure code [B@BCZK] Drop in Engine Coolant Level

Failure code [B@BCZK] Drop in Engine Coolant Level

Action level E01 Failure code B@BCZK Failure Drop in engine coolant level (Monitor panel controller system)

40-16

Detail of failure Low coolant level is indicated Action of controller Problem on machine Related information No.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Low coolant level warning is output (false detection) a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor q This failure code is issued before the engine is started Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector GR17 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Check if indication goes out when a jumper wire is connected between coolant level sensor (GR17) (female) (1) and (2) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector FC04 and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between FC04 (female) (10) and Max. 1 z GR17 (female) (1) Resistance Wiring harness between GR17 (female) (2) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector JR21 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between JR21 (male) (6) and (1) Resistance Max. 1 z 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting.

Coolant level below low level or defective coolant level sensor

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective joint connector JR2 or JR7

4 Defective monitor panel controller

FC04 Between (10) and ground

Quantity of coolant Normal Insufficient

Voltage Max 1 V 17 30 V

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Troubleshooting by failure code Failure code [B@BCZK] Drop in Engine Coolant Level

Related circuit diagram

40-167

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40-167

Troubleshooting by failure code Failure code [b@C5ZK] Low brake fluid level (before engine start)

Failure code [b@C5ZK] Low brake fluid level (before engine start)
Action level E01 Failure code b@C5ZK Failure Brake oil level too low (before engine start) (KOMTRAX Plus controller system)

40-168

Detail of failure Low brake oil level is indicated before the engine is started Action of controller Problem on machine Related information No.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Warning output constantly (false detection) a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor q This failure code is issued before the engine is started Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR10 and connect T-adapter. Front brake oil level too low or 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 1. Prepare with starting switch at OFF position. 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 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector HR6 or HR10 and each connector to be disconnected in turn. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 3 (wire breakage or defective conWiring harness between V3B (female) (5) and tact of connector) Max. 1 z HR10 (female) (1) Resistance Wiring harness between V3B (female) (5) and HR6 Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V3A, V3B and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 4 Defective KOMTRAX Plus controller V3A, V3B Between V3A (5) and ground Between V3B (5) and ground Oil level Normal Insufficient Voltage Max 1 V 17 30 V

Related circuit diagram

40-168

40-168

WA1200-6

Troubleshooting by failure code 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 level E03 Failure code B@C5ZK Failure Low front or rear brake fluid level (while engine is running) (KOMTRAX Plus controller system)

Detail of failure Low brake oil level is indicated while the engine is running Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Warning output constantly (false detection) a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor q This failure code is issued while the engine is running Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR10 and connect T-adapter. Front brake oil level too low or 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 1. Prepare with starting switch at OFF position. 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 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector HR6 or HR10 and each connector to be disconnected in turn. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 3 (wire breakage or defective conWiring harness between V3B (female) (5) and tact of connector) Max. 1 z HR10 (female) (1) Resistance Wiring harness between V3A (female) (5) and HR6 Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V3A, V3B and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 4 Defective KOMTRAX Plus controller V3A,V3B Between V3A (5) and ground Between V3B (5) and ground Oil level Normal Insufficient Voltage Max 1 V 17 30 V

Related circuit diagram

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40-169

Troubleshooting by failure code Failure code [B@C6NS] High brake oil temp.

Failure code [B@C6NS] High brake oil temp.

Action level E02 Detail of failure Action of controller Problem on machine Related information No.
q

40-170

Failure code B@C6NS

Failure

Brake oil overheating (Monitor panel controller system)

Overheating of oil temperature is detected by signals from brake oil temperature sensor while engine is running. Brake oil temperature caution lamp turns ON in red. Brake comes not to work. If machine is used as it is, brake may be damaged. Input signals from oil temperature sensor can be checked by using monitoring function. (Code: 30201( C), 30204(V)) For troubleshooting of brake oil temperature sensor, see failure code [DGR2KX] Cause Procedure, measuring location, criteria and remarks Brakes may be overloaded. Check corresponding parts. Perform troubleshooting for failure codes [DGR2KA] and [DGR2KX]. If no failure is found in checks on causes 1 and 2, monitor panel controller may be defective.

q q q q q

1 Brake cooling oil overheating 2 Defective brake oil temperature sensor

3 Defective monitor panel controller

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Troubleshooting by failure code Failure code [b@CENS] High torque converter oil temp.

Failure code [b@CENS] High torque converter oil temp.

Action level E02 Failure code b@CENS Failure Torque converter oil temperature is high (above 120 C) (Monitor panel controller system)

40-171

Detail of failure An overheat of torque converter oil temperature (above 120 C) is indicated Action of controller Problem on machine
q q q

Turns the centralized warning lamp and alarm buzzer ON.

Torque converter oil temperature gauge constantly indicates a temperature above 120 C Alarm screen false output a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T24 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T24 (male) Between (1) and (2) Engine oil temperature Normal temperature (25 C) 120 C Resistance Approx. 40 z Approx. 2.2 z

Torque converter oil temperature is above 120 C or defective 1 torque converter oil temperature sensor

Ground fault in wiring harness (Contact with ground circuit)

3 Defective monitor panel controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and other connectors in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC05 Resistance Min. 1 Mz (female) (2) to T24 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. FC05 (female) Between (2) and ground Resistance Min. 1 Mz

Related circuit diagram

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40-171

Troubleshooting by failure code Failure code [B@CENS] Very high torque converter oil temp.

Failure code [B@CENS] Very high torque converter oil temp.

Action level E02 Failure code B@CENS Failure Torque converter oil temperature is high (above 130 C) (Monitor panel controller system)

40-172

Detail of failure An overheat of torque converter oil temperature (above 130 C) is indicated Action of controller Problem on machine
q q q

Turns the centralized warning lamp and alarm buzzer ON.

Torque converter oil temperature gauge constantly indicates a temperature above 130 C Alarm screen false output a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor No. Cause Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector T24 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T24 (male) Between (1) and (2) Engine oil temperature Normal temperature (25 C) 130 C Resistance Approx. 40 z Approx. 1.7 z

Torque converter oil temperature is above 120 C or defective 1 torque converter oil temperature sensor

Ground fault in wiring harness (Contact with ground circuit)

3 Defective monitor panel controller

1. Turn starting switch to OFF position. 2. Disconnect connector FC05 and other connectors in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC05 Resistance Min. 1 Mz (female) (2) to T24 (female) (1) 1. Turn starting switch to OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. FC05 (female) Between (2) and ground Resistance Min. 1 Mz

Related circuit diagram

40-172

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Troubleshooting by failure code Failure code [B@CENS] Very high torque converter oil temp.

WA1200-6

40-173

Troubleshooting by failure code Failure code [B@GAZK] Low battery 1 fluid level

Failure code [B@GAZK] Low battery 1 fluid level

Action level E01 Failure code B@GAZK Failure Low battery electrolyte level [1] (KOMTRAX Plus controller system)

40-174

Detail of failure Low battery electrolyte level [1] is indicated Action of controller Problem on machine Related information No.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Wrong alarm output a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor q When battery electrolyte level is normal Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector RA9 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. RA9 (male) Between (1) and ground Voltage 5.56.5 V

Low battery charge or defective battery electrolyte level sensor [1]

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2B to RA9 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V2B (female) (1) and RA9 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2B to RA9 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V2B (female) (1) to RA9 (female) (1) Resistance Min. 1 Mz

1. Prepare with starting switch at OFF position. 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 Between (1) and ground Min. 1 Mz

40-174

WA1200-6

Troubleshooting by failure code Failure code [B@GAZK] Low battery 1 fluid level

Related circuit diagram

40-175

WA1200-6

40-175

Troubleshooting by failure code Failure code [B@GBZK] Low battery 2 fluid level

Failure code [B@GBZK] Low battery 2 fluid level

Action level E01 Failure code B@GBZK Failure Low battery electrolyte level [2] (KOMTRAX Plus controller system)

40-176

Detail of failure Low battery electrolyte level [2] is indicated Action of controller Problem on machine Related information No.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Wrong alarm output a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor q When battery electrolyte level is normal Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector RA8 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. R08 (male) Between (1) and ground Voltage 5.5 6.5 V

Low battery charge or defective battery electrolyte level sensor [2]

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2B to RA8 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V2B (female) (2) and RA8 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2B to RA8 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V2B (female) (2) to RA8 (female) (1) Resistance Min. 1 Mz

1. Prepare with starting switch at OFF position. 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 Between (2) and ground Min. 1 Mz

40-176

WA1200-6

Troubleshooting by failure code Failure code [B@GBZK] Low battery 2 fluid level

Related circuit diagram

40-17

WA1200-6

40-177

Troubleshooting by failure code Failure code [B@GCZK] Low battery 3 fluid level

Failure code [B@GCZK] Low battery 3 fluid level

Action level E01 Failure code B@GCZK Failure Low battery electrolyte level [3] (KOMTRAX Plus controller system)

40-178

Detail of failure Low battery electrolyte level [3] is indicated Action of controller Problem on machine Related information No.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Wrong alarm output a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor q When battery electrolyte level is normal Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector RA7 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. RA7 (male) Between (1) and ground Voltage 5.5 6.5 V

Low battery charge or defective battery electrolyte level sensor [3]

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2B to RA7 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V2B (female) (3) and RA7 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2B to RA7 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V2B (female) (3) to RA7 (female) (1) Resistance Min. 1 Mz

1. Prepare with starting switch at OFF position. 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 Between (3) and ground Min. 1 Mz

40-178

WA1200-6

Troubleshooting by failure code Failure code [B@GCZK] Low battery 3 fluid level

Related circuit diagram

40-179

WA1200-6

40-179

Troubleshooting by failure code Failure code [B@HANS] High hydraulic oil temp.

Failure code [B@HANS] High hydraulic oil temp.

Action level E02 Failure code B@HANS Failure Abnormally high hydraulic oil temperature (overheat) (Monitor panel controller system)

40-180

Detail of failure An overheat of hydraulic oil temperature (above 105 C) is indicated Action of controller Problem on machine
q q q

Turns the centralized warning lamp and alarm buzzer ON.

Hydraulic oil temperature gauge constantly indicates a temperature above 105 C Wrong alarm output a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HS1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Hydraulic oil temperature is above 1 105 C or defective hydraulic oil temperature sensor HS1 (male) Engine oil temperature Normal temperature (25 C) Between (1) and (2) 100 C 120 C Resistance Approx. 37 50 kz Approx. 3.5 4.0 kz Approx. 3.0 3.6 kz

Ground fault in wiring harness (Contact with ground circuit)

3 Defective monitor panel controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector HS1 form connector FC05 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC05 Resistance Min. 1 Mz (female) (7) to HS1 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. FC05 (female) Between (7) and ground Resistance Min. 1 Mz

Related circuit diagram

40-180

40-180

WA1200-6

Troubleshooting by failure code Failure code [B@HAZK] Low hydraulic oil level

Failure code [B@HAZK] Low hydraulic oil level

Action level E01 Failure code B@HAZK Failure Low hydraulic oil level (Monitor panel controller system)

40-181

Detail of failure Low hydraulic oil level is indicated while machine is operating. Action of controller Problem on machine Related information No.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Warning outputs constantly. (false detection) a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter is restored, and no failure code is displayed on monitor q This failure code appears before engine is started Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connector HS5 and connect T-adapter. Low oil level or defective hydraulic 1 3. Turn starting switch to ON position and perform troubleshooting. oil level sensor Check if indication goes out when hydraulic oil level sensor (HS5) (female) (1) is grounded. 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector FC04 and each connector to be disconOpen circuit in wiring harness nected in turn. 2 (wire breakage or defective con3. 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) 1. Prepare with starting switch at OFF position. 2. Disconnect FC04 connector and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective monitor panel controller FC04 Between FC04 (2) and ground Oil level Normal Insufficient Voltage Max 1 V 17 to 30 V

Related circuit diagram

40-181

WA1200-6

40-181

Troubleshooting by failure code Failure code [D191KA] Neutral Output Relay Disconnection

Failure code [D191KA] Neutral Output Relay Disconnection

Action level E01 Detail of failure Action of controller Problem on machine Related information
q

40-182

Failure code D191KA

Failure

AJSS neutral safety relay: open circuit (Boom bucket & AJSS controller system)

Signal is not output to neutral safety relay due to open circuit in AJSS neutral safety relay output system If cause of failure disappears, machine becomes normal by itself. While operating AJSS lever, engine can be started (steering moves immediately after engine starts) The neutral safety relay does not function if the AJSS neutral position adjustment (initial setting) has not been performed Method of reproducing failure code: Operate AJSS lever while engine is stopped Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector L127 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L127 (male) Between (1) and (2) Resistance 200 to 400 z

q q

q q

No.

Defective AJSS neutral safety 1 relay (L127) (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, L127 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness 2 Between ground and wiring harness from L07 (contact with power supply circuit) Voltage Max. 1 V (female) (4) to L27 (female) (1) Wiring harness between L127 (female) (2) and Resistance Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 Voltage Between (4) and ground 20 to 30 V

40-182

WA1200-6

Troubleshooting by failure code Failure code [D191KA] Neutral Output Relay Disconnection

Related circuit diagram

40-183

WA1200-6

40-183

Troubleshooting by failure code Failure code [D191KB] Neutral Output Relay hot short

Failure code [D191KB] Neutral Output Relay hot short

Action level E01 Detail of failure Action of controller Problem on machine Related information
q q q q q q q

40-184

Failure code D191KB

Failure

AJSS neutral safety relay: short circuit (Boom bucket & AJSS controller system)

Abnormal current flows because of ground fault in AJSS neutral safety relay output system. Turns the output to the AJSS neutral safety relay OFF. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. While operating AJSS lever, engine can be started (steering moves immediately after engine starts) The neutral safety relay does not function if the AJSS neutral position adjustment (initial setting) has not been performed While an error is occuring the controller does not output power. Method of reproducing failure code: Operate AJSS lever while engine is stopped Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector L127 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L127 (male) Between (1) and (2) Between (1), (2) and ground Resistance 200 to 400 z Min. 1 Mz

No.

Defective AJSS neutral safety 1 relay (L127) (Internal open circuit)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02-127 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Resistance Min. 1 Mz (female) (4) to L127 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 Between (4) and ground Voltage 20 to 30 V

40-184

WA1200-6

Troubleshooting by failure code Failure code [D191KB] Neutral Output Relay hot short

Related circuit diagram

40-185

WA1200-6

40-185

Troubleshooting by failure code 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 level E01 Detail of failure Action of controller Problem on machine Related information No. Cause Procedure, measuring location, criteria and remarks Failure code D19MKA Failure Switch pump PNC solenoid relay: open circuit, ground fault (Boom bucket & AJSS controller system)

Due to open circuit or ground fault in the switch pump PNC solenoid system, no current flows when the switch pump PNC solenoid is energized.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect L69 relay, replace with a normally operating relay, and connect Defective switch pump PNC soleT-adapter. 1 noid relay (internal open circuit) 3. Turn starting switch to ON position and perform troubleshooting. Replace with a normally operating Failure code disappears relay. 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR31, HR32 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between L06 (female) (16) and Max. 1 z tact of connector) HR32 (female) (1) Resistance Wiring harness between L06 (female) (26) and Max. 1 z HR31 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR31, HR32 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L06 3 Min. 1 Mz (Contact with ground circuit) (female) (16) to HR32 (female) (1) Resistance Between ground and wiring harness from L06 Min. 1 Mz (female) (26) to HR31 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L06 (female) Between (16), (26) and ground Resistance Min. 1 Mz

Defective boom bucket & AJSS controller

40-186

WA1200-6

Troubleshooting by failure code Failure code [D19MKA] SW pump PNC solenoid Relay (Disconnect/Short Circuit)

Related circuit diagram

40-187

WA1200-6

40-187

Troubleshooting by failure code Failure code [D19MKY] SW pump PNC solenoid Relay hot short

Failure code [D19MKY] SW pump PNC solenoid Relay hot short

Action level E01 Failure code D19MKY Failure Switch pump PNC solenoid relay: hot short circuit (Boom bucket & AJSS controller system)

40-18

Detail of failure Hot short circuit has occurred in switch pump PNC solenoid system Action of controller Problem on machine Related information No. Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect relay L69 and replace with a normally operating relay. Defective switch pump PNC sole1 3. Turn starting switch to ON position and perform troubleshooting. noid relay (internal short circuit) Replace with a normally operating Failure code disappears relay. 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR31, HR32 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 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 Between ground and wiring harness from L06 Max. 1 V (female) (26) to HR31 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L06 (female) Between (16), (26) and ground Resistance Min. 1 Mz

Defective boom bucket & AJSS controller

40-188

WA1200-6

Troubleshooting by failure code Failure code [D19MKY] SW pump PNC solenoid Relay hot short

Related electrical circuit diagram

40-189

WA1200-6

40-189

Troubleshooting by failure code Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure

Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure

Action level E01 Failure code D19MMA Failure Switch pump PNC solenoid 1: ground fault, or hot short circuit (Boom bucket & AJSS controller system)

40-190

Detail of failure An error has occurred in switch pump PNC solenoid system Action of controller Problem on machine Related information No. Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR31 and connect T-adapter. 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) 515 z

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR31 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between L06 (female) (26) and Max. 1 z tact of connector) HR31 (female) (1) Resistance Wiring harness between HR31 (female) (2) and Max. 1 z JR3 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR31 and connect T-adapter. 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 L06 Resistance Min. 1 Mz (female) (26) to HR31 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR32 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L06 4 Max. 1 V (contact with 24 V circuit) (female) (26) to HR32 (female) (1) Voltage Between ground and wiring harness from HR31 Max. 1 V (female) (2) to JR3 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L06 (female) Between (26) and ground Resistance Min. 1 Mz

Defective boom bucket & AJSS controller

40-190

WA1200-6

Troubleshooting by failure code Failure code [D19MMA] SW pump PNC solenoid circuit 1 Failure

Related electrical circuit diagram

40-191

WA1200-6

40-191

Troubleshooting by failure code Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure

Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure

Action level E01 Failure code D19MMB Failure Switch pump PNC solenoid 2: open circuit, ground fault, or hot short circuit (Boom bucket & AJSS controller system)

40-192

Detail of failure An error has occurred in switch pump PNC solenoid system Action of controller Problem on machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR32 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. R32 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Defective switch pump PNC solenoid 2 (internal short circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR32 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between L06 (female) (16) and Max. 1 z tact of connector) HR32 (female) (1) Resistance Wiring harness between HR32 (female) (2) and Max. 1 z JR3 (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR32 and connect T-adapter. 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 L06 Resistance Min. 1 Mz (female) (26) to HR32 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR32 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L06 4 Max. 1 V (contact with 24 V circuit) (female) (16) to HR32 (female) (1) Voltage Between ground and wiring harness from HR32 Max. 1 V (female) (2) to JR3 (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L06 (female) Between (16), (26) and ground Resistance Min. 1 Mz

Defective boom bucket & AJSS controller

40-192

WA1200-6

Troubleshooting by failure code Failure code [D19MMB] SW pump PNC solenoid circuit 2 Failure

Related electrical circuit diagram

40-193

WA1200-6

40-193

Troubleshooting by failure code Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)

Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)

WA1200-6

40-194

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q

Failure code B5ZHKA

Failure

Terminal C signal: open circuit, ground fault (Transmission controller system)

Open circuit or ground fault in terminal C system (engine speed is above 500 rpm rpm and no starting switch terminal C signal has been input.) None in particular If cause of failure disappears, machine becomes normal by itself. The engine does not start. Input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with monitoring function (Code: 40905 D-IN-7) (Transmission controller system). Method of reproducing failure code: Set the starting switch to START position Cause Procedure, measuring location, criteria and remarks If fuse is blown, circuit may have ground fault. (See cause 4.) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FCL1 and connect T-adapter. 3. Turn starting switch to ON, OFF, and START positions to perform troubleshooting. FCL1 Between (1) and (6) Starting switch START OFF, ON Resistance Max. 1 z Min. 1 Mz

q q q q q

1 Defective fuse (1)

Defective starting switch (Internal open circuit)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

5 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect each connector and connect T-adapter. 3. Start engine and perform troubleshooting Wiring harness between FCL1 (female) (5) and L57 Max. 1 z (female) (5) 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) 1. Prepare with starting switch at OFF position. 2. Disconnect each connector and connect T-adapter. 3. Start engine and perform troubleshooting Between ground and wiring harness from FCL1 (female) (5) to L57 (female) (5), and to circuit Min. 1 Mz branch end Between ground and wiring harness from L57 (female) (3) to L127 (female) (3), and to circuit Resistance Min. 1 Mz branch end Between ground and wiring harness from L127 (female) (3) to L02 (female) (6), and to circuit Min. 1 Mz branch end point 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON, OFF, and START positions to perform troubleshooting. L02 Between (6) and ground Starting switch START OFF, ON Voltage 20 to 30 V Max. 1V

40-194

WA1200-6

Troubleshooting by failure code Failure code [D5ZHKA] Starting Switch C signal circuit (Disconnect/Short Circuit)

Related circuit diagram

40-195

WA1200-6

40-195

Troubleshooting by failure code Failure code [D5ZHKB] Starting Switch C signal circuit Hot short

Failure code [D5ZHKB] Starting Switch C signal circuit Hot short

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-196

Failure code B5ZHKB

Failure

Terminal C signal: hot short circuit (Transmission controller system)

Hot short circuit in terminal C system (engine speed is above 500 rpm and starting switch terminal C signal has been input.). Stops engine starting aid function. If cause of failure disappears, machine becomes normal by itself. The engine does not start. Input state (ON/OFF) from starting switch terminal C to transmission controller can be checked with monitoring function (Code: 40905 D-IN-7) (Transmission controller system). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector FCL1 and connect T-adapter. 3. Turn starting switch to ON, OFF, and START positions to perform troubleshooting. FCL1 Between (1) and (6) Starting switch START OFF, ON Resistance Max. 1 z Min. 1 Mz

Defective starting switch (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect each connector and connect T-adapter. 3. Start engine and perform troubleshooting Between ground and wiring harness from FCL1 (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 Voltage (female) (3) to L127 (female) (6), and to circuit Max. 1 V branch end Between ground and wiring harness from L57 (female) (3) to L02 (female) (6), and to circuit Max. 1 V branch end point 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON, OFF, and START positions to perform troubleshooting. 3 Defective transmission controller L02 Starting switch Voltage Between (6) and ground START OFF, ON 20 to 30 V Max. 1 V

40-196

WA1200-6

Troubleshooting by failure code Failure code [D5ZHKB] Starting Switch C signal circuit Hot short

Related circuit diagram

40-197

WA1200-6

40-197

Troubleshooting by failure code Failure code [D5ZHKZ] Starting Switch C signal circuit failure

Failure code [D5ZHKZ] Starting Switch C signal circuit failure

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-198

Failure code B5ZHKZ

Failure

Terminal C signal: short circuit (Work equipment controller system)

Hot short circuit in terminal C system (engine speed is above 500 rpm and starting switch terminal C signal has been input.). Stops engine starting aid function. If cause of failure disappears, machine becomes normal by itself. The engine does not start. Input condition (ON/OFF) to work equipment controller from starting switch terminal C can be checked with monitoring function (Code: 40905 D-IN-7) (Work equipment controller system). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector FCL1 and connect T-adapter. 3. Turn starting switch to ON, OFF, and START positions to perform troubleshooting. FCL1 Between (1) and (6) Starting switch START OFF, ON Resistance Max. 1 z Min. 1 Mz

Defective starting switch (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect each connector and connect T-adapter. 3. Start engine and perform troubleshooting Between ground and wiring harness from FCL1 (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 Voltage (female) (3) to L127 (female) (6), and to circuit Max. 1 V branch end Between ground and wiring harness from L127 (female) (6) to L06 (female) (25), and to circuit Max. 1 V branch end point 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn starting switch to ON, OFF, and START positions to perform troubleshooting. Defective work equipment control3 L06 Starting switch Voltage ler Between (25) and ground START OFF, ON 20 to 30 V Max. 1 V

40-198

WA1200-6

Troubleshooting by failure code Failure code [D5ZHKZ] Starting Switch C signal circuit failure

Related circuit diagram

40-19

WA1200-6

40-199

Troubleshooting by failure code Failure code [D5ZHL6] Ignition C terminal Circuit Failure

Failure code [D5ZHL6] Ignition C terminal Circuit Failure

Action level E01 Failure code D5ZHL6 Failure Prelubrication system error (input signal out of range) (Machine monitor system)

40-20

Detail of failure Open circuit or ground fault has occurred in prelubrication system Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect the following connectors and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness 1 (wire breakage or defective contact of connector) Wiring harness between FC02 (female) (2) and FCL1 (6) and L127 (female) (3) Wiring harness between starting switch (BR) and LR11 (female) (1) Wiring harness between starting switch (C) and L57 (female) (5) Max. 1 z Resistance Max. 1 z Max. 1 z
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect the following connectors and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC02 Min. 1 Mz (female) (2) to FCL1 (6) and to L127 (female) (3) Between ground and wiring harness from starting Resistance Min. 1 Mz switch (BR) to LR11 (female) (1) Between ground and wiring harness from starting switch (C) to L57 (female) (5) Min. 1 Mz

40-200

WA1200-6

Troubleshooting by failure code Failure code [D5ZHL6] Ignition C terminal Circuit Failure

Related electrical circuit diagram

40-201

WA1200-6

40-201

Troubleshooting by failure code Failure code [DAF5KP] Monitor Panel 5 V source sys Error

Failure code [DAF5KP] Monitor Panel 5 V source sys Error

Action level E01 Failure code DAF5KP Failure Lift arm angle sensor power supply error (Monitor panel controller system)

40-202

Detail of failure Ground fault has occurred in lift arm angle sensor power supply circuit Action of controller Problem on machine Related information No. Cause Ground fault in wiring harness (contact with ground circuit) Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC01, F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC01 Resistance Min. 1 Mz (female) (16) to FC04 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC01 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. FC01 (16)(6) Voltage Min. 4.5 5 V
q

Detail of failure is displayed in yellow on the multi-monitor screen.

2 Defective monitor panel controller

Related electrical circuit diagram

40-202

40-202

WA1200-6

Troubleshooting by failure code Failure code [DAF5KP] Monitor Panel 5 V source sys Error

WA1200-6

40-203

Troubleshooting by failure code Failure code [DAFRKR] Communication Lost Monitor Panel Controller

Failure code [DAFRKR] Communication Lost Monitor Panel Controller 40-204

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

Failure code DAFRKR

Failure

CAN-NET signal communication error (monitor panel controller) (Monitor panel controller system)

Communication via CAN signal line between the machine monitor and transmission controller is defective. Uses CAN information that was sent from monitor panel controller before the occurrence of the error. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. The monitor does not display normally Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Connect T-adapter between connectors FC06 and L03. 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 L03 (female) (22) and Max. 1 z tact of connector) FC06 (female) (8) Resistance Wiring harness between L03 (female) (32) and Max. 1 z FC06 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between FC06 and L03 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness 2 Between ground and wiring harness from L03 (contact with ground circuit) Min. 1 Mz (female) (22) to FC06 (female) (8) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (32) to FC06 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between FC06 and L03 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness 3 Between ground and wiring harness from L03 (contact with 24 V circuit) Max. 1 V (female) (22) to FC06 (female) (8) Voltage Between ground and wiring harness from L03 Max. 1 V (female) (32) to FC06 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. FC06 (female) Between (3) and (8) Resistance Min. 1 Mz

Contact with wiring harness (Between CANH and CANL)

5 Defective terminationg resistance

1. Prepare with starting switch at OFF position. 2. Disconnect connector CAN1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. CAN1 (male) Between (A) and (B) Resistance 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, troubleshooting cannot be performed.)

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Troubleshooting by failure code Failure code [DAFRKR] Communication Lost Monitor Panel Controller

Related circuit diagram

40-205

WA1200-6

40-205

Troubleshooting by failure code Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source

Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source

Action level E03
q

40-206

Failure code DAQ0KK

Failure

Transmission controller: Power supply voltage drop (Transmission controller system)

Detail of failure

q q q

Action of controller Problem on machine Related information No. 1

Unswitched power supply voltage (power supply directly from battery) of the transmission controller drops. Voltage of UNSW power supply (battery direct power supply) is below 18 V and engine speed is 500 rpm or more. Cannot detect the input signals correctly. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). The machine cannot operate normally. Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks If the circuit breaker is open, the circuit probably has ground fault, etc. (See Cause No. 4.) If fuse is blown, circuit may have ground fault. (See cause 4.) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to battery relay and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between LH battery relay circuit breaker CBF4 and RH battery relay circuit breaker Max. 1 z CB8 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 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to battery relay and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between LH battery relay circuit Min. 1 Mz breaker CBF4 and RH battery relay circuit breaker CB8 Wiring harness between circuit breaker CBF4 fuse 2 and circuit breaker CBF8 fuse 1 Resistance Min. 1 Mz

q q

Circuit breaker (CBF4, CBF8) open

2 Blown fuse 1-4 or fuse 2-8

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

5 Defective transmission controller

Wiring harness between fuse 2 (8) L04 (female) (2), Min. 1 Mz fuse 1 (4) L04 (female) (1), and circuit branch end 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-branch. 3. Turn starting switch to ON position and perform troubleshooting. L04 Between (1), (11) and ground Between (2), (12), (22) and ground Voltage 20 to 30 V

40-206

WA1200-6

Troubleshooting by failure code Failure code [DAQ0KK] Drop in Transmission Controller Main Power Source

Related circuit diagram

40-207

WA1200-6

40-207

Troubleshooting by failure code Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal

Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal

Action level E01 Failure code DAQ0KT Failure Nonvolatile memory (EEPROM) writing error (Transmission controller system)

40-208

Detail of failure Internal failure of transmission controller. Action of conInterrupts learning and uses default data. troller Problem on machine Related information No. Gear shifting shocks. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed, connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks Gearshift shock is reduced by learning.

1 Defective transmission controller

40-208

WA1200-6

Troubleshooting by failure code Failure code [DAQ0KT] Nonvolatile Memory (EEPROM) Abnormal

WA1200-6

40-209

Troubleshooting by failure code Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source

Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source 40-210
Action level E03 Failure code DAQ2KK Failure Controller solenoid powersupply voltage drop (Transmission controller system)

Detail of failure Controller solenoid powersupply voltage has dropped Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, AL3, AR4 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (2) and AL3 Wiring harness between L04 (female) (1) and AR4 Resistance Max. 1 z Max. 1 z
q

Turns the centralized warning lamp and alarm buzzer ON.

Open circuit in wiring harness (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, AL3, AR4 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L04 (contact with ground circuit) Min. 1 Mz (female) (2) to AL3 Resistance Between ground and wiring harness from L04 Min. 1 Mz (female) (1) to AR4 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, AL3, AR4 and connect T-adapter. Short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (contact between harnesses) Wiring harness between L04 (female) (2) and AL3, Resistance Min. 1 Mz and between L04 (female) (1) and AR4 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, AL3, AR4 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L04 (connection with 24 V circuit) Max. 1 V (female) (2) to AL3 Voltage Between ground and wiring harness from L04 Max. 1 V (female) (1) to AR4 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective transmission controller L04 (female) Voltage Between (1), (2) and ground Max. 1 V

40-210

WA1200-6

Troubleshooting by failure code Failure code [DAQ2KK] Drop in Transmission Controller Solenoid Power Source

Related electrical circuit diagram

40-21

WA1200-6

40-211

Troubleshooting by failure code Failure code [DAQRKR] Communication Lost T/M Controller

Failure code [DAQRKR] Communication Lost T/M Controller

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-212

Failure code DAQRKR

Failure

CAN-NET signal communication error (transmission controller) (Transmission controller system)

Communication via CAN signal line between the machine monitor and transmission controller is defective. For CAN information from transmission controller, uses lase value obtained before failure. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. The monitor does not display normally Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Connect T-adapter between connectors FC06 and L03. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (wire breakage or defective con- Wiring harness between L03 (female) (22) and Max. 1 z tact of connector) FC06 (female) (8) Resistance Wiring harness between L03 (female) (32) and Max. 1 z FC06 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between FC06 and L03 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L03 (contact with ground circuit) Min. 1 Mz (female) (22) to FC06 (female) (8) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (32) to FC06 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between FC06 and L03 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L03 (contact with 24 V circuit) Max. 1 V (female) (22) to FC06 (female) (8) Voltage Between ground and wiring harness from L03 Max. 1 V (female) (32) to FC06 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Contact with wiring harness (Between CANH and CANL) FC06 (female) Resistance Between (3) and (8) Min. 1 Mz 1. Prepare with starting switch at OFF position. 2. Disconnect connector CAN1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. CAN1 (male) Between (A) and (B) Resistance 120 12 z

5 Defective terminationg 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, troubleshooting cannot be performed.)

40-212

WA1200-6

Troubleshooting by failure code Failure code [DAQRKR] Communication Lost T/M Controller

Related circuit diagram

40-213

WA1200-6

40-213

Troubleshooting by failure code Failure code [DAQRMA] Defective Option Selection Data in Transmission

Failure code [DAQRMA] Defective Option Selection Data in Transmission 40-214

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

Failure code DAQRMA

Failure

Option setting for transmission controller: Malfunction (Machine monitor - transmission controller)

Option settings information sent from machine monitor when starting switch is turned to ON position differ from option settings stored in controller. Gear speed is held in Neutral. Option settings stored in controller are used for control. Condition is not recovered until starting switch is turned to OFF position. Gear speed is set to Neutral and restart becomes unable. Perform initial setting and initial adjustments in the same way when replacing the transmission controller. Cause Procedure, measuring location, criteria and remarks Defective setting of transmission controller options

Defective setting of transmission 1 controller

40-214

WA1200-6

Troubleshooting by failure code Failure code [DAQRMA] Defective Option Selection Data in Transmission

WA1200-6

40-215

Troubleshooting by failure code Failure code [DB2RKR] Communication Lost Engine Controller

Failure code [DB2RKR] Communication Lost Engine Controller

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-216

Failure code DB2RKR

Failure

CAN communication with transmission controller: communication failure (failure in target component system) (Transmission controller - engine controller system)

Communication failure in CAN signal line between engine controller and transmission controller For CAN information from transmission controller, uses lase value obtained before failure. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. The monitor does not display normally Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Connect T-adapter between connectors L06 and E3. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (22) and E3 Max. 1 z (female) (A) Resistance Wiring harness between L03 (female) (32) and E3 Max. 1 z (female) (B) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between L06 and E3 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Min. 1 Mz (female) (22) to E3 (female) (A) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (32) to E3 (female) (B)

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors between L06 and E3 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L03 3 Max. 1 V (contact with 24 V circuit) (female) (22) to E3 (female) (A) Voltage Between ground and wiring harness from L03 Max. 1 V (female) (32) to E3 (female) (B) 1. Prepare with starting switch at OFF position. 2. Disconnect connector E3 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. E3 (female) Between (A) and (B) Resistance Min. 1 Mz

Contact with wiring harness (Between CANH and CANL)

5 Defective terminationg resistance

1. Prepare with starting switch at OFF position. 2. Disconnect connector CAN1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. CAN1 (male) Between (A) and (B) Resistance 120 12 z

6 Defective transmission controller

a If no failure is found by above diagnoses on causes 1 to 5, transmission controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-216

WA1200-6

Troubleshooting by failure code Failure code [DB2RKR] Communication Lost Engine Controller

Related circuit diagram

40-217

WA1200-6

40-217

Troubleshooting by failure code Failure code [DB90KK] Drop in Work Controller Main Power Source

Failure code [DB90KK] Drop in Work Controller Main Power Source

Action level E03 Detail of failure
q q q

40-218

Failure code DB90KK

Failure

Work equipment controller: low power supply voltage (input) (Work equipment controller system)

Action of controller

q q q

Voltage of work equipment controller UNSW power supply (battery direct power supply) is low. Voltage of UNSW power supply (battery direct power supply) is 18 V or less. 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. Even if cause of failure disappears, machine does not become normal until AJSS lever and work equipment control lever are set to N (NEUTRAL). Turns the centralized warning lamp and alarm buzzer ON. Normal operation is impossible because it cannot detect the input signals correctly. The machine cannot operate normally. Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks If the circuit breaker is open, the circuit probably has ground fault, etc. (See Cause No. 4.) If fuse is blown, circuit may have ground fault. (See cause 4.) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to battery relay and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between LH battery relay circuit breaker CBF4 and RH battery relay circuit breaker Max. 1 z CB8 Wiring harness between circuit breaker CBF4 fuse Resistance Max. 1 z 2 and circuit breaker CBF8 fuse 1 Wiring harness between fuse 2 (8) L07 (female) (2), fuse 1 (4) L07 (female) (1), and circuit branch end Max. 1 z

Problem on machine Related information No. 1

q q

Circuit breaker (CBF4, CBF8) open

2 Blown fuse 1-4 or fuse 2-8

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to battery relay and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between LH battery relay circuit breaker CBF4 and RH battery relay circuit breaker Min. 1 Mz CB8 Wiring harness between circuit breaker CBF4 fuse Resistance 2 and circuit breaker CBF8 fuse 1 Min. 1 Mz

Wiring harness between fuse 2 (8) L07 (female) (2), Min. 1 Mz fuse 1 (4) L07 (female) (1), and circuit branch end 1. Prepare with starting switch at OFF position. 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 Between (2), (12), (22) and ground 20 to 30 V

40-218

WA1200-6

Troubleshooting by failure code Failure code [DB90KK] Drop in Work Controller Main Power Source

Related circuit diagram

40-219

WA1200-6

40-219

Troubleshooting by failure code Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal

Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal

Action level E01 Detail of failure Action of controller Problem on machine Related information No. 1
q q q q q q

40-2 0

Failure code DB90KT

Failure

Boom bucket & AJSS controller non-volatile memory: internal failure of controller (Boom bucket & AJSS controller system)

Error occurs in non-volatile memory of controller. Controls machine by applying default values to machine model selection and option settings. Detail of failure is displayed in yellow on the multi-monitor screen. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Errors may be detected wrongly. Performance lowers because work equipment is controlled by improper data.

Cause Defective boom bucket & AJSS controller

Procedure, measuring location, criteria and remarks Since this is internal failure, troubleshooting cannot be performed. Replace controller.

40-220

WA1200-6

Troubleshooting by failure code Failure code [DB90KT] Nonvolatile Memory (EEPROM) Abnormal

WA1200-6

40-221

Troubleshooting by failure code Failure code [DB92KK] Solenoid Voltage Failure (Work controller)

Failure code [DB92KK] Solenoid Voltage Failure (Work controller)

Action level E03 Failure code DB92KK Failure Controller solenoid powersupply voltage drop (Boom bucket & AJSS controller system)

40-2 2

Detail of failure Controller solenoid powersupply voltage has dropped Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, AR4, AL3 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (1) and AR4 Wiring harness between L07 (female) (2) and AL3 Resistance Max. 1 z Max. 1 z
q

Turns the centralized warning lamp and alarm buzzer ON.

Open circuit in wiring harness (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, AR4, AL3 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L07 (contact with ground circuit) Min. 1 Mz (female) (2) to AL3 Resistance Between ground and wiring harness from L07 Min. 1 Mz (female) (1) to AR4 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, AR4, AL3 and connect T-adapter. Short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (contact between harnesses) Wiring harness between L07 (female) (1) and AR4, Resistance Min. 1 Mz and between L07 (female) and AL3 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, AR4, AL3 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L07 Max. 1 V (connection with 24 V circuit) (female) (2) to AL3 Voltage Between ground and wiring harness from L07 Max. 1 V (female) (1) to AR4 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS controller L07 (female) Voltage Between (1), (2) and ground Max. 1 V

40-222

WA1200-6

Troubleshooting by failure code Failure code [DB92KK] Solenoid Voltage Failure (Work controller)

Related electrical circuit diagram

40-2 3

WA1200-6

40-223

Troubleshooting by failure code Failure code [DB95KX] 5 V source sys Error (Work controller)

Failure code [DB95KX] 5 V source sys Error (Work controller)

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q

40-2 4

Failure code DB95KX

Failure

Sensor 5 V power supply (1) input signal out of range (Boom bucket & AJSS controller system)

5 V sensor power supply system is out of normal voltage output range (outside 4.7 to 5.3 V) Input signals cannot be sensed properly due to failure of potentiometer signal. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. The work equipment does not work at all. The potentiometer errors described below occur. Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 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) 46 kz 1. Prepare with starting switch at OFF position. 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 Between (B) and (C) 46 kz 1. Prepare with starting switch at OFF position. 2. Disconnect connector S04 and connect T-adapter. Defective lift arm EPC lever poten3. Turn the starting switch to OFF position, then perform troubleshooting. 3 tiometer S03 (male) Resistance tor (internal open or short circuit) Between (4) and (1) 2.53.9 kz 1. Prepare with starting switch at OFF position. 2. Disconnect connector S02 and connect T-adapter. Defective bucket EPC lever poten3. Turn the starting switch to OFF position, then perform troubleshooting. 4 tiometer S02 (male) Resistance tor (internal open or short circuit) Between (4) and (1) Ground fault in wiring harness (contact with ground circuit) 2.53.9 kz 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (22) and Resistance Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 Between (22) and (10) Voltage 4.85 to 5.15 V

Defective boom bucket & AJSS controller

40-224

WA1200-6

Troubleshooting by failure code Failure code [DB95KX] 5 V source sys Error (Work controller)

Related circuit diagram

40-2 5

WA1200-6

40-225

Troubleshooting by failure code Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller

Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller 40-2 6
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

CAN communication with transmission controller: communication failure Failure (abnormality in objective component system) (Transmission controller - boom bucket & AJSS controller sysDB9RKR tem) Communication via CAN signal line between the boom bucket & AJSS controller and transmission controller is defective For CAN information from transmission controller, uses lase value obtained before failure. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. Failure code The monitor does not display normally Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Connect T-adapter between connectors L03 and L06. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (22) and L06 Max. 1 z (female) (22) Resistance Wiring harness between L03 (female) (32) and L06 Max. 1 z (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between L03 and L06 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Min. 1 Mz (female) (22) and L06 (female) (22) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (32) and L06 (female) (3)

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors between L03 and L06 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness 3 Between ground and wiring harness from L03 (contact with 24 V circuit) Max. 1 V (female) (22) and L06 (female) (22) Voltage Between ground and wiring harness from L03 Max. 1 V (female) (32) and L06 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L06 (female) Between (22) and (32) Resistance Min. 1 Mz

Contact with wiring harness (Between CANH and CANL)

5 Defective terminationg resistance

1. Prepare with starting switch at OFF position. 2. Disconnect connector CAN1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. CAN1 (male) Between (A) and (B) Resistance 120 12 z

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, troubleshooting cannot be performed.)

40-226

WA1200-6

Troubleshooting by failure code Failure code [DB9RKR] Communication Lost Boom Bucket & Joy stick Controller

Related circuit diagram

40-2 7

WA1200-6

40-227

Troubleshooting by failure code 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 level E03 Detail of failure Action of controller Problem on machine Related information No. 1
q q q q

Failure code DB9RMA

Failure

Boom bucket & AJSS controller option setting: malfunction (Machine monitor - boom bucket & AJSS controller)

Option setting information sent from machine monitor when starting switch is turned to ON position differs from option setting stored in controller. Option settings stored in controller are used for control. Turns the centralized warning lamp and alarm buzzer ON. Condition is not recovered until starting switch is turned to OFF position.

Perform initial setting and initial adjustments in the same way when replacing boom bucket & AJSS controller. Cause Procedure, measuring location, criteria and remarks Defective setting of boom bucket & AJSS controller options

Defective setting of boom bucket & AJSS controller

40-228

WA1200-6

Troubleshooting by failure code Failure code [DB9RMA] Defective Option Selection Data in Boom Bucket Controller

WA1200-6

40-229

Troubleshooting by failure code Failure code [DB9RMC] Communication Lost (Work Controller)

Failure code [DB9RMC] Communication Lost (Work Controller)

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-230

Failure code DB9RMC

Failure

CAN communication malfunction (Boom bucket & AJSS controller system)

Communication via CAN signal line between the boom bucket & AJSS controller and transmission controller is defective Uses CAN information that was sent from boom bucket controller before the occurrence of the error. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. The monitor does not display normally Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, L06 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (wire breakage or defective con- Wiring harness between L03 (female) (22) and L06 Max. 1 z tact of connector) (female) (22) Resistance Wiring harness between L03 (female) (32) and L06 Max. 1 z (female) (32) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, L06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L03 (contact with ground circuit) Min. 1 Mz (female) (22) and L06 (female) (22) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (32) and L06 (female) (32) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, L06 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L03 Max. 1 V (connection with 24 V circuit) (female) (22) and L06 (female) (22) Voltage Between ground and wiring harness from L03 Max. 1 V (female) (32) and L06 (female) (32) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Contact with wiring harness (Between CANH and CANL) L06 (female) Resistance Between (22) and (32) Min. 1 Mz 1. Prepare with starting switch at OFF position. 2. Disconnect connector CAN1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. CAN1 (male) Between (A) and (B) Resistance 120 12 z

5 Defective terminationg resistance

Defective boom bucket & AJSS controller

a If no failure is found in above diagnoses for causes 1 to 5, boom bucket & AJSS controller may be defective. (Since this is an internal defect, troubleshooting cannot be performed.)

40-230

WA1200-6

Troubleshooting by failure code Failure code [DB9RMC] Communication Lost (Work Controller)

Related electrical circuit diagram

40-231

WA1200-6

40-231

Troubleshooting by failure code Failure code [DBB0KK] VHMS source voltage Error

Failure code [DBB0KK] VHMS source voltage Error

Action level E03 Failure code DBB0KK Failure KOMTRAX Plus power supply abnormal (KOMTRAX Plus controller system)

40-232

Detail of failure Power supply circuit voltage dropped while KOMTRAX Plus engine speed is above 500 rpm. Action of controller Problem on machine
q

Turns the centralized warning lamp and alarm buzzer ON.

When there is an open circuit Data cannot be saved (problem occurs when both of 2 wires are open) 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 inforfor ground fault) q Open circuit in KOMTRAX Plus ground line harness is unlikely to occur since there are multiple mation poles. Exclude it from probable causes
q

No.

Cause

Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector V1 and each connector to be disconnected Open circuit in wiring harness in turn. 1 (wire breakage or defective con- 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (6) - FS1 (10) tact of connector) - fuse - FS1 (1) - battery relay terminal (AL04) - bat- Resistance Max. 1 z tery (+) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector V1 and each connector to be disconnected in turn. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness V1 (female) (6) - FS1 (10) - fuse - FS1 (1) - battery relay terminal Voltage 20 30 V (AL04) - battery (+) 1. Prepare with starting switch at OFF position. 2. Disconnect connector V1 and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn starting switch to ON position and perform troubleshooting. 3 ler V1 Voltage Between (6), (7) and ground 20 30 V

40-232

WA1200-6

Troubleshooting by failure code Failure code [DBB0KK] VHMS source voltage Error

Related circuit diagram

40-23

WA1200-6

40-233

Troubleshooting by failure code Failure code [DBB0KQ] VHMS Connector Mismatch

Failure code [DBB0KQ] VHMS Connector Mismatch

Action level E03 Failure code DBB0KQ Failure Improper connection of KOMTRAX Plus select connector (KOMTRAX Plus controller system)

40-234

Detail of failure Disagreement of model selection signals occurs. Action of controller Problem on machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector JR21 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between each pin of JR21 (male) Resistance Max. 1 z 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector V2B, V3A and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between wiring harnesses between V2B (female) Resistance Min. 1 Mz (12), V3A (female) (9) and RA4 (female) (1) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector V2B, V3A and each connector to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V2B Resistance Min1 Mz (female) (12), V3A (female) (9) to RA4 (female) (1)
q

Turns the centralized warning lamp and alarm buzzer ON.

1 Defective joint connector (JR21)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

40-234

WA1200-6

Troubleshooting by failure code Failure code [DBB0KQ] VHMS Connector Mismatch

Related circuit diagram

40-235

WA1200-6

40-235

Troubleshooting by failure code Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V)

Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V)40-236

Action level E03 Failure code DBB3KK Failure Backup power supply for KOMTRAX Plus abnormal (KOMTRAX Plus controller system)

Detail of failure Voltage drop occurs in KOMTRAX Plus backup power supply circuit. Action of controller Problem on machine
q q

Turns the centralized warning lamp and alarm buzzer ON.

Related information

When fuse I (10) is not blown (if blown, check wiring harness between fuse and KOMTRAX Plus for ground fault) Open circuit in KOMTRAX Plus ground line harness is unlikely to occur since there are multiple poles. Exclude it from probable causes Cause Procedure, measuring location, criteria and remarks

No.

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector V1 and each connector to be disconnected Open circuit in wiring harness in turn. 1 (wire breakage or defective con- 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (6) (7) - FS1 tact of connector) (10) - fuse - FS1 (1) - battery relay terminal (AL04) - Resistance Max. 1 z battery (+) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector V1 and each connector to be disconnected in turn. Ground fault in wiring harness 2 3. Turn the starting switch to OFF position, then perform troubleshooting. (contact with ground circuit) Between ground and wiring harness V1 (female) (6) (7) - FS1 (10) - fuse - FS1 (1) - battery relay termi- Resistance Min. 1 Mz nal (AL04) - battery (+) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector V1 and each connector to be disconnected in turn. Defective KOMTRAX Plus control3. Turn starting switch to ON position and perform troubleshooting. 3 ler V1 Voltage Between (6), (7) and ground 20 to 30 V

40-236

WA1200-6

Troubleshooting by failure code Failure code [DBB3KK] Abnormality in VBAT voltage (VHMS VBAT<10V)

Related circuit diagram

40-237

WA1200-6

40-237

Troubleshooting by failure code Failure code [DBB5KP] VHMS 5 V source sys Error

Failure code [DBB5KP] VHMS 5 V source sys Error

Action level E01 Failure code DBB5KP Failure KOMTRAX Plus sensor power supply (5 V) abnormal (KOMTRAX Plus controller system)

40-238

Detail of failure Low output voltage appears in KOMTRAX Plus sensor power supply (5 V) circuit. Action of controller
q q

Interrupts output Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Value of sensor using power supply abnormal machine Related information No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 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. 1. Turn starting switch to OFF position. 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 (contact with ground circuit) Between ground and wiring harness between V1 Resistance Min. 1 Mz (female) (4) and MT1 (female) (B) 1. Turn starting switch to OFF position. 2. Disconnect V1 and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn starting switch to ON position and perform troubleshooting. 3 ler V1 Voltage Between (4) and ground 4 to 6 V

40-238

WA1200-6

Troubleshooting by failure code Failure code [DBB5KP] VHMS 5 V source sys Error

Related circuit diagram

40-239

WA1200-6

40-239

Troubleshooting by failure code Failure code [DBB6KP] VHMS 24 V source sys Error

Failure code [DBB6KP] VHMS 24 V source sys Error

Action level E01 Failure code DBB6KP Failure KOMTRAX Plus sensor power supply (24 V) abnormal (KOMTRAX Plus controller system)

40-240

Detail of failure Low output voltage appears in KOMTRAX Plus sensor power supply (24 V) circuit Action of controller
q q

Interrupts output Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Value of sensor using power supply abnormal machine Related information No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position. 2. Disconnect each connector Sensor that caused indication to 3. Turn starting switch to ON position and perform troubleshooting. go out is defective Check if indication goes out when sensor MT2, 3, 4, HR15, 16, HS3, or 4 is disconnected individually 1. Turn starting switch to OFF position. 2. Disconnect each connector Defective joint connector (JT2, 3. Perform troubleshooting as is JR14, or JL2) Between pins JT2 (male), JR14 (male), and JR3 Resistance Max. 1 z (male) 1. Turn starting switch to OFF position. 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 (female) (5) to JR14 (female) (1) Ground fault in wiring harness Between ground and wiring harness from JT2 (contact with ground circuit) (female) (2), (3), (4), (5) to MT4 (female) (2), MT3 Min. 1 Mz Resistance (female) (2), MT2 (female) (2) Between ground and wiring harness from JR14 (female) (2), (3), (4), (5), (6) to HS4 (female) (2), Min. 1 Mz HS3 (female) (2), HR16 (female) (2), HR15 (female) (2) 1. Turn starting switch to OFF position. 2. Disconnect connector V1 and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn starting switch to ON position and perform troubleshooting. ler V1 Voltage Between (2) and ground 2225 V

40-240

WA1200-6

Troubleshooting by failure code Failure code [DBB6KP] VHMS 24 V source sys Error

Related circuit diagram

40-241

WA1200-6

40-241

Troubleshooting by failure co Failure code [DBB7KP] VHMS 12 V source sys Error

Failure code [DBB7KP] VHMS 12 V source sys Error

Troubleshooting by failure co 40-242 WA1200-6

40-242

Action level E01

Failure code DBB7KP

Failure

KOMTRAX Plus sensor power supply (12 V) abnormal (KOMTRAX Plus controller system)

Detail of failure Low output voltage appears in KOMTRAX Plus sensor power supply (12 V) circuit. Action of controller
q q

Interrupts output Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Value of sensor using power supply abnormal machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Turn starting switch to ON position and perform troubleshooting. Check if indication goes out when wheel speed sensor (F15) is disconnected. 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1, FL2, F15 and connect T-adapter in turn. Ground fault in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (Contact with ground circuit) Between ground and wiring harness between V1 Resistance Min. 1 Mz (female) (3) and F15 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector V1 and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn starting switch to ON position and perform troubleshooting. 3 ler V1 Voltage Between (3) and ground 11 to 13 V

1 Defective wheel speed sensor

Related circuit diagram

40-242

40-242

WA1200-6

Troubleshooting by failure co Failure code [DBBQMC] Communication Lost (VHMS CAN0)

Failure code [DBBQMC] Communication Lost (VHMS CAN0)

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-243

Failure code DBBQMC

Failure

CAN communication malfunction (KOMTRAX Plus controller system)

Communication via CAN signal line between the KOMTRAX Plus controller and machine monitor is defective. Uses CAN information that was sent from KOMTRAX Plus controller before the occurrence of the error. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. The monitor does not display normally Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connectors V4A, M7 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (wire breakage or defective con- Wiring harness between V4A (female) (6) and M7 Max. 1 z tact of connector) (female) (9) Resistance Wiring harness between V4A (female) (14) and M7 Max. 1 z (female) (10) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V4A, M7 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from V4A (contact with ground circuit) Min. 1 Mz (female) (6) to M7 (female) (9) Resistance Between ground and wiring harness from V4A Min. 1 Mz (female) (14) to M7 (female) (10) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V4A, M7 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from V4A Max. 1 V (connection with 24 V circuit) (female) (6) to M7 (female) (9) Voltage Between ground and wiring harness from V4A Max. 1 V (female) (14) to M7 (female) (10) 1. Prepare with starting switch at OFF position. 2. Disconnect connector V4A and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Contact with wiring harness (Between CANH and CANL) V4A (female) Resistance Between (6) and (14) Min. 1 Mz 1. Prepare with starting switch at OFF position. 2. Disconnect connector CAN1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. CAN1 (male) Between (A) and (B) Resistance 12012 z

5 Defective terminationg resistance

a If no failure is found in above diagnoses for causes 1 to 5, KOMTRAX Plus Defective KOMTRAX Plus control6 controller may be defective. (Since this is an internal defect, troubleshootler ing cannot be performed.)

WA1200-6

40-243

Troubleshooting by failure co Failure code [DBBQMC] Communication Lost (VHMS CAN0)

Related electrical circuit diagram

40-24

40-244

WA1200-6

Troubleshooting by failure co Failure code [DBBRKR] Communication Lost VHMS Controller

Failure code [DBBRKR] Communication Lost VHMS Controller

Action level E03
q

40-245

Failure code DBBRKR

Failure

CAN-NET signal communication error (KOMTRAX Plus) (Machine monitor system)

Machine monitor cannot obtain information from KOMTRAX Plus controller through CAN commuDetail of failure nication circuit. Action of conq Holds information at the time of occurrence of failure. troller Problem on machine Related information No.
q q q

System may not operate properly. Information from KOMTRAX Plus controller is not displayed. Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1 Perform troubleshooting for failure Code [DAFRKR].

WA1200-6

40-245

Troubleshooting by failure co Failure code [DBBRMC] Communication Lost (VHMS CAN1)

Failure code [DBBRMC] Communication Lost (VHMS CAN1)

Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-246

Failure code DBBRMC

Failure

CAN communication malfunction (KOMTRAX Plus controller system)

Communication via CAN signal line between the machine monitor and KOMTRAX Plus controller is defective. Uses CAN information that was sent from KOMTRAX Plus controller before the occurrence of the error. Turns the centralized warning lamp and alarm buzzer ON. If cause of failure disappears, machine becomes normal by itself. The monitor does not display normally Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connectors V4A, FC06 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (wire breakage or defective con- Wiring harness between V4A (female) (4) to FC06 Max. 1 z tact of connector) (female) (3) Resistance Wiring harness between V4A (female) (12) to FC06 Max. 1 z (female) (8) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V4A, FC06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from V4A (contact with ground circuit) Min. 1 Mz (female) (4) to FC06 (female) (3) Resistance Between ground and wiring harness from V4A Min. 1 Mz (female) (12) to FC06 (female) (8) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V4A, FC06 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from V4A Max. 1 V (connection with 24 V circuit) (female) (4) to FC06 (female) (3) Voltage Between ground and wiring harness from V4A Max. 1 V (female) (12) to FC06 (female) (8) 1. Prepare with starting switch at OFF position. 2. Disconnect connector V4A and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Contact with wiring harness (Between CANH and CANL) V4A (female) Resistance Between (4) and (12) Min. 1 Mz 1. Prepare with starting switch at OFF position. 2. Disconnect connector CAN1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. CAN1 (male) Between (A) and (B) Resistance 120 12 z

5 Defective terminationg resistance

a If no failure is found in above diagnoses for causes 1 to 5, KOMTRAX Plus Defective KOMTRAX Plus control6 controller may be defective. (Since this is an internal defect, troubleshootler ing cannot be performed.)

40-246

WA1200-6

Troubleshooting by failure co Failure code [DBBRMC] Communication Lost (VHMS CAN1)

Related electrical circuit diagram

40-247

WA1200-6

40-247

Troubleshooting by failure co Failure code [DD10KX] Verification Mode SW Failure

Failure code [DD10KX] Verification Mode SW Failure

Action level E01 Failure code DD10KX Failure Inspection mode switch system error (input signal out of range) (Transmission controller system)

40-248

Detail of failure Open circuit or ground fault has occurred in the inspection mode switch circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (28) and 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 (male) (2) tact of connector) Resistance Wiring harness between L04 (female) (33) and Max. 1 z CHK (male) (1) Wiring harness between L04 (female) (40) and Max. 1 z CHK (male) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (28) and Min. 1 Mz CHK (male) (4) Hot short circuit in wiring harness 2 Wiring harness between L04 (female) (9) and CHK (contact with ground circuit) Min. 1 Mz (male) (2) Resistance Wiring harness between L04 (female) (33) and Min. 1 Mz CHK (male) (1) Wiring harness between L04 (female) (40) and Min. 1 Mz CHK (male) (3)

Related electrical circuit diagram

40-248

40-248

WA1200-6

Troubleshooting by failure co Failure code [DD10KX] Verification Mode SW Failure

WA1200-6

40-249

Troubleshooting by failure co Failure code [DD1ALD] Remote positioner upper side set sw failure

Failure code [DD1ALD] Remote positioner upper side set sw failure

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q q

40-250

Failure code DD1ALD

Failure

Remote positioner RAISE/LOWER stop position set switches (RAISE): LOWER stop position set switch error (Boom bucket & AJSS controller system)

RAISE stop position cannot be set due to ground fault in remote positioner RAISE stop position set switch system (RAISE) Cancels setting operation of lift arm RAISE stop position. Cancels remote RAISE stop function. Turns off lift arm RAISE stop pilot lamp. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Setting of lift arm RAISE stop position for remote positioner is disabled. Remote positioner RAISE stop function does not work. Input (ON/OFF) from remote positioner RAISE/LOWER (RAISE) stop position set switch can be checked by using monitoring function. (Code: 40913 D-IN-28) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S12 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Remote positioner S12 (male) RAISE/LOWER stop Resistance position set switches Between (5) and (6) Between (6) and ground RAISE Other than above Ladder at any position Max. 1 z Min. 1 Mz Min. 1 Mz

Defective remote positioner RAISE/LOWER (RAISE) stop 1 position set switch (Internal short circuit)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, S12 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L06 Resistance Min. 1 Mz (female) (13) to S12 (female) (6) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Remote positioner L06 (male) RAISE/LOWER stop Voltage position set switches Between (13) and ground RAISE Other than above Max. 1 V 710 V

40-250

WA1200-6

Troubleshooting by failure co Failure code [DD1ALD] Remote positioner upper side set sw failure

Related circuit diagram

40-251

WA1200-6

40-251

Troubleshooting by failure co Failure code [DD1BLD] Remote positioner lower side set sw failure

Failure code [DD1BLD] Remote positioner lower side set sw failure

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q q

40-252

Failure code DD1BLD

Failure

Remote positioner RAISE/LOWER stop position set switches (LOWER): LOWER stop position set switch error (Boom bucket & AJSS controller system)

LOWER stop position cannot be set due to ground fault in remote positioner RAISE/LOWER (RAISE) stop position set switch circuit. Cancels setting operation of lift arm LOWER stop position. Cancels remote LOWER stop function. Turns off lift arm LOWER stop pilot lamp. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Setting of lift arm LOWER stop position for remote positioner is disabled. Remote positioner LOWER stop function does not work. Input (ON/OFF) from remote positioner RAISE/LOWER (LOWER) stop position set switch can be checked by using monitoring function. (Code: 40913 D-IN-29) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S12 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Remote positioner S12 (male) RAISE/LOWER stop Resistance position set switches Between (4) and (5) Between (4) and ground LOWER Other than above Ladder at any position Max. 1 z Min. 1 Mz Min. 1 Mz

Defective remote positioner RAISE/LOWER stop position set 1 switches (Internal short circuit)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, S12 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L06 Resistance Min. 1 Mz (female) (3) to S12 (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Remote positioner L06 (male) RAISE/LOWER stop Voltage position set switches Between (3) and ground LOWER Other than above Max. 1 V 710 V

40-252

WA1200-6

Troubleshooting by failure co Failure code [DD1BLD] Remote positioner lower side set sw failure

Related circuit diagram

40-253

WA1200-6

40-253

Troubleshooting by failure co Failure code [DDA7L4] Throttle Lock Input signal Short Circuit

Failure code [DDA7L4] Throttle Lock Input signal Short Circuit

Action level E01 Detail of failure Action of controller Problem on machine
q q q q q

40-254

Failure code DDA7L4

Failure

RPM set ON/OFF switch: ON/OFF signals disagree. (Transmission controller system)

RPM set does not function because of a hot short circuit in RPM set ON/OFF switch system. Turns RPM set function OFF. If cause of failure disappears, machine becomes normal by itself. RPM setting can not be made. Input condition (ON/OFF) from RPM set ON/OFF switch (pressed upward) can be checked with monitoring function (Code: 44200 THROT LOCK A). Input condition (ON/OFF) from RPM set ON-OFF switch (pressed downward) can be checked with monitoring function (Code: 44201 THROT LOCK B). Method of reproducing failure code: Set the starting switch to ON position + Set the RPM set ON/OFF switch to ON position Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S18 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S18 (male) RPM set ON/OFF switch ON OFF ON OFF Resistance Min. 1 Mz Max. 1 z Max. 1 z Min. 1 Mz

Related information

q q

No.

Defective RPM set ON/OFF switch (internal short circuit)

Between (4) and (5)

Between (5) and (6)

Between (4), (5), (6) and Ladder at any position Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, S18 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L02 2 Max. 1 V (contact with 24 V circuit) (female) (13) to S18 (female) (4) Voltage Between ground and wiring harness from L02 Max. 1 V (female) (19) to S18 (female) (6) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 3 Defective transmission controller Between (13) and ground RPM set ON/OFF switch ON OFF ON OFF Voltage Max. 1 V 20 to 30 V 20 to 30 V Max. 1 V

Between (19) and ground

40-254

WA1200-6

Troubleshooting by failure co Failure code [DDA7L4] Throttle Lock Input signal Short Circuit

Related electrical circuit diagram

40-25

WA1200-6

40-255

Troubleshooting by failure co Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit

Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q

40-256

Failure code DDA8KB

Failure

RPM set idle-up/down selector switch (idle-down): short circuit (Transmission controller system)

Idle-up does not function because of ground fault in RPM set idle-up/down selector switch (idle-up) system. Turns RPM set function OFF. If cause of failure disappears, machine becomes normal by itself. RPM setting can not be made. Input condition (ON/OFF) from RPM set idle-up/down selector switch can be checked with monitoring function (Code: 40906 D-IN-13 D-IN-14). 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) Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S19 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. RPM set idle-up/down S19 (male) Resistance selector switch Between (5) and (6) At idle-up position At idle-down position Max. 1 z Min. 1 Mz

q q q q q

Defective RPM set idle-up/down 1 selector switch (internal short circuit)

Between (4), (6) and Ladder at any position Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, S19 and connect T-adapter. Ground fault in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (contact with ground circuit) Between ground and wiring harness from L04 Resistance Min. 1 Mz (female) (19) to S19 (female) (6) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. RPM set idle-up/down L04 Voltage selector switch 3 Defective transmission controller At idle-up position Between (19) and ground Idle-down position or NEUTRAL Max. 1 V 710 V

40-256

WA1200-6

Troubleshooting by failure co Failure code [DDA8KB] Throttle Lock (set/accelerator) switch Short Circuit

Related circuit diagram

40-257

WA1200-6

40-257

Troubleshooting by failure co Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit

Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q

40-258

Failure code DDA9KB

Failure

RPM set idle-up/down selector switch (idle-down): short circuit (Transmission controller system)

Engine speed cannot be set to optional speed because of ground fault in RPM set idle-up/down selector switch system. Turns RPM set function OFF. If cause of failure disappears, machine becomes normal by itself. RPM setting can not be made. Input condition (ON/OFF) from RPM set idle-up/down selector switch can be checked with monitoring function (Code: 40906 D-IN-13 D-IN-14). 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) Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S19 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.

q q q q q

Defective RPM set idle-up/down 1 selector switch (internal short circuit)

S19 (male)

RPM set idle-up/down selector switch At idle-up position At idle-down position

Resistance Min. 1 Mz Max. 1 z

Between (4) and (5)

Ground fault in wiring harness (contact with ground circuit)

Between (4), (6) and Ladder at any position Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, S19 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L04 Resistance Min. 1 Mz (female) (29) to S19 (female) (6) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L04 RPM set idle-up/down selector switch Idle-up position or Neutral At idle-down position Voltage 710 V Max. 1 V

3 Defective transmission controller

Between (29) and ground

40-258

WA1200-6

Troubleshooting by failure co Failure code [DDA9KB] Throttle Lock (set/decelerator) switch Short Circuit

Related circuit diagram

40-259

WA1200-6

40-259

Troubleshooting by failure co Failure code [DDB6L4] Neutral Signal Malfunction

Failure code [DDB6L4] Neutral Signal Malfunction

Action level E03 Failure code DDB6L4 Failure Neutralizer signal system error (Transmission controller system)

40-260

Detail of failure Open circuit or ground fault has occurred in neutralizer signal circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector L59 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L59 (male) Between (3), (5) and ground Resistance Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective parking brake safety relay

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

4 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, FC09, HR14 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Min. 1 Mz (female) (6) to FC09 (female) (3) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (6) to HR14 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, FC09, HR14 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Min. 1 Mz (female) (6) to FC09 (female) (3) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (6) to HR14 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L03(female) Between (6) and ground Voltage 20 to 30 V

40-260

WA1200-6

Troubleshooting by failure co Failure code [DDB6L4] Neutral Signal Malfunction

Related electrical circuit diagram

40-261

WA1200-6

40-261

Troubleshooting by failure co Failure code [DDD7KA] Speed control dial circuit (Low Voltage)

Failure code [DDD7KA] Speed control dial circuit (Low Voltage)

Action level E01 Failure code DDD7KA Failure Travel speed control dial system error (input signal out of range) (Transmission controller system)

40-262

Detail of failure Open circuit or ground fault has occurred in the travel speed sensor circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC16 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective travel speed sensor FC16 (male) Between (1) and (3) Between (1) and (2) Change frame angle Resistance 0.2 5 kz 0 5 kz
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L04, FC16 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L02 (female) (14) and Max. 1 z FC16 (female) (2) Resistance Wiring harness between L04 (female) (34) and Max. 1 z FC16 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L04, FC06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L02 (female) (14) to FC16 (female) (2) Between ground and wiring harness from L04 (female) (34) to FC16 (female) (1) Min. 1 Mz Resistance Min. 1 Mz

Ground fault in wiring harness (Contact with ground circuit)

4 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 (female) (4)(14) Voltage 4.9 5.1 V

40-262

WA1200-6

Troubleshooting by failure co Failure code [DDD7KA] Speed control dial circuit (Low Voltage)

Related circuit diagram

40-263

WA1200-6

40-263

Troubleshooting by failure co Failure code [DDD7KB] Speed control dial circuit (High Voltage)

Failure code [DDD7KB] Speed control dial circuit (High Voltage)

Action level E01 Failure code DDD7KB Failure Travel speed control dial system error (input signal out of range) (Transmission controller system)

40-264

Detail of failure Hot short circuit has occurred in travel speed sensor circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC16 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.. 1 Defective travel speed sensor FC16 (male) Between (1) and (3) Between (1) and (2) Change frame angle Resistance 0.2 5 kz 0 5 kz
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L04, FC16 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 Hot short circuit in wiring harness Between ground and wiring harness from L02 (contact with 5 V circuit) (female) (14) to FC16 (female) (2) Between ground and wiring harness from L04 (female) (34) to FC16 (female) (1) Max. 1 V Voltage Max. 1 V

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L04 (female) (4)(14) Voltage 4.9 5.1 V

Related circuit diagram

40-264

40-264

WA1200-6

Troubleshooting by failure co Failure code [DDD7KB] Speed control dial circuit (High Voltage)

WA1200-6

40-265

Troubleshooting by failure co Failure code [DDDBKA] Traction control dial circuit (Low Voltage)

Failure code [DDDBKA] Traction control dial circuit (Low Voltage)

Action level E01
q

40-26

Failure code DDDBKA

Failure

Traction adjustment dial: open circuit, ground fault (Transmission controller system)

Detail of failure Action of controller Problem on machine Related information

q q

Traction adjustment is disabled because of open circuit or ground fault in traction adjustment dial system (Traction adjustment dial signal voltage: max. 0.3 V) Uses traction adjustment dial value immediately before failure is detected. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). Traction adjustment is disabled Input (%) from traction adjustment dial can be checked by using monitoring function. (Code: 94000 TRACTION DIAL) Input (voltage) from traction adjustment dial can be checked by using monitoring function. (Code: 94001 TRACTION DIAL) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC15 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. FC15 (male) Dial position Ladder at any position Ladder at any position Between (2) and (3) MAX MIN Voltage 4.75 to 5.25V 0.5 4.5 V 0.51.0 V 4.04.5 V

q q q q

No.

Defective traction adjustment dial 1 (internal open circuit)

Between (1) and (3)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L04, FC15 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L02 (female) (3) and Max. 1 z FC15 (female) (2) Wiring harness between L02 (female) (4) and FC15 Resistance Max. 1 z (female) (3) Wiring harness between L04 (female) (34) and Max. 1 z FC15 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, FC15 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L02 Min. 1 Mz (female) (3) to FC15 (female) (2) Resistance Between ground and wiring harness from L04 Min. 1 Mz (female) (34) to FC15 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 Between (3) and ground Dial position Ladder at any position Voltage 4.75 to 5.25V

4 Defective transmission controller

40-266

WA1200-6

Troubleshooting by failure co Failure code [DDDBKA] Traction control dial circuit (Low Voltage)

Related circuit diagram

40-267

WA1200-6

40-267

Troubleshooting by failure co Failure code [DDDBKB] Traction control dial circuit (High Voltage)

Failure code [DDDBKB] Traction control dial circuit (High Voltage)

Action level E01 Detail of failure Action of controller Problem on machine Related information
q q q

40-268

Failure code DDDBKB

Failure

Traction adjustment dial: hot short circuit (Transmission controller system)

Traction adjustment is disabled because of open circuit in traction adjustment dial system. (Traction adjustment dial signal voltage: max. 0.3 V) Uses traction adjustment dial value immediately before failure is detected. Even if cause of failure disappears, machine does not become normal until directional lever or directional selector switch is set to N (NEUTRAL). Traction adjustment is disabled Input (%) from traction adjustment dial can be checked by using monitoring function. (Code: 94000 TRACTION DIAL) Input (voltage) from traction adjustment dial can be checked by using monitoring function. (Code: 94001 TRACTION DIAL) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC15 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. FC15 (male) Dial position Ladder at any position Ladder at any position Between (2) and (3) MAX MIN Voltage 4.75 to 5.25V 0.5 4.5 V 0.51.0 V 4.04.5 V

q q q q

No.

Defective traction adjustment dial 1 (internal open circuit)

Between (1) and (3)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, FC15 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Hot short circuit in wiring harness 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) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller L02 Dial position Voltage Between (3) and ground Ladder at any position 4.75 to 5.25V

40-268

WA1200-6

Troubleshooting by failure co Failure code [DDDBKB] Traction control dial circuit (High Voltage)

Related circuit diagram

40-269

WA1200-6

40-269

Troubleshooting by failure co Failure code [DDE5MA] Emergency steering signal Failure

Failure code [DDE5MA] Emergency steering signal Failure

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q

40-270

Failure code DDE5MA

Failure

Emergency steering drive switch: malfunction (Machine monitor system)

When the engine stops, the steering pump pressure is detected because of the ground fault in the emergency steering drive switch system. None in particular Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. The emergency steering operates. Input condition (ON/OFF) from emergency steering motor can be checked with monitoring function (Code: 40903 D-IN-30). Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors R11, R12 and connect T-adapter. 3. Start engine and perform troubleshooting q Relieve the steering circuit Steering circuit R11, R12 (male) Resistance relief pressure When oil pressure is Min. 1 Mz abnormal (low) Between (1) and (2) When oil pressure is norMax. 1 z mal Between (1), (2) and Ladder at any position Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC04, R12, R11 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC04 (female) (3) to R12 (female) and to R11 female (11), Resistance Min. 1 Mz (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC02 and connect T-adapter. 3. Start engine and perform troubleshooting q Relieve the steering circuit Steering circuit FC04 (female) Voltage relief pressure When oil pressure is 20 to 30 V abnormal (low) Between (3) and ground When oil pressure is norMax. 1 V mal

q q q

Defective emergency steering 1 drive switch (internal defect)

Ground fault in wiring harness (contact with ground circuit)

3 Defective machine monitor

40-270

WA1200-6

Troubleshooting by failure co Failure code [DDE5MA] Emergency steering signal Failure

Related circuit diagram

40-271

WA1200-6

40-271

Troubleshooting by failure co Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection

Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection

Action level E03 Failure code DDK4KA Failure AJSS FNR seesaw switch system error (input signal out of range) (Transmission controller system)

40-272

Detail of failure Open circuit or ground fault has occurred in AJSS FNR seesaw switch circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S31 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between S31 (female) (2), (3), (4) and ground Resistance Min. 1 Mz 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (16) and S31 Max. 1 z (female) (4) 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) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Min. 1 Mz (female) (16) to S31 (female) (4) Between ground and wiring harness from L03 Resistance Min. 1 Mz (female) (26) to S31 (female) (3) Between ground and wiring harness from L03 Min. 1 Mz (female) (36) to S31 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L03(female) Between (16), (26), (36) and ground Resistance Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

1 Defective FNR seesaw switch

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

4 Defective transmission controller

40-272

WA1200-6

Troubleshooting by failure co Failure code [DDK4KA] AJSS F/N/R Input Signal Disconnection

Related electrical circuit diagram

40-273

WA1200-6

40-273

Troubleshooting by failure co Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit

Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit

Action level E03 Failure code DDK4KB Failure AJSS FNR seesaw switch system error (input signal out of range) (Transmission controller system)

40-274

Detail of failure Hot short circuit has occurred in AJSS FNR seesaw switch circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S31 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between S31 (female) (2), (3), (4) and ground Resistance Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

1 Defective FNR seesaw switch

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L03 Max. 1 V 2 (Defective contact with 24 V cir(female) (5) to S31 (female) (5) Between ground and wiring harness from L03 cuit) Voltage Max. 1 V (female) (15) to S31 (female) (6) Between ground and wiring harness from L03 Max. 1 V (female) (25) to S31 (female) (7) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 3 Defective transmission controller L03(female) Resistance Between (16), (26), (36) and ground Min. 1 Mz

40-274

WA1200-6

Troubleshooting by failure co Failure code [DDK4KB] AJSS F/N/R Input Signal Short Circuit

Related electrical circuit diagram

40-275

WA1200-6

40-275

Troubleshooting by failure co Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)

Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)

Action level E01 Failure code DDK5L4 Failure AJSS upshift system error (input signal out of range) (Transmission controller system)

40-276

Detail of failure Open circuit, ground fault, or hot short circuit has occurred in AJSS upshift circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect connector S31 and connect T-adapter. Defective AJSS upshift 3. Turn starting switch to ON position and perform troubleshooting. Between S31 (female) (5), (15), (25), (35) and Resistance Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (5) and S31 Max. 1 z Open circuit in wiring harness (female) (5) (wire breakage or defective con- Wiring harness between L03 (female) (15) and S31 Max. 1 z tact of connector) (female) (6) Resistance Wiring harness between L03 (female) (25) and S31 Max. 1 z (female) (7) Wiring harness between L03 (female) (35) and S31 Max. 1 z (female) (8) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L03 Min. 1 Mz (female) (5) to S31 (female) (5) Ground fault in wiring harness Between ground and wiring harness from L03 (contact with ground circuit) Min. 1 Mz (female) (15) to S31 (female) (6) Resistance Between ground and wiring harness from L03 Min. 1 Mz (female) (25) to S31 (female) (7) Between ground and wiring harness from L03 Min. 1 Mz (female) (35) to S31 (female) (8) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L03 Max. 1 V (female) (5) to S31 (female) (5) Hot short circuit in wiring harness Between ground and wiring harness from L03 (contact with 24 V circuit) Max. 1 V (female) (15) to S31 (female) (6) Voltage Between ground and wiring harness from L03 Max. 1 V (female) (25) to S31 (female) (7) Between ground and wiring harness from L03 Max. 1 V (female) (35) to S31 (female) (8)

40-276

WA1200-6

Troubleshooting by failure co Failure code [DDK5L4] Joystick Shift up/down SW circuit (Disconnect/Short Circuit)

No.

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, S31 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L03 (female) Between (5), (15), (25), (35) and ground Resistance Min. 1 Mz

5 Defective transmission controller

Related electrical circuit diagram

40-27

WA1200-6

40-277

Troubleshooting by failure co 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 level E01 Detail of failure Action of controller Problem on machine Related information No.
q

Failure code DDP5KA

Failure

Lock detection pressure switch for steering lock lever: open circuit, hot short circuit (Transmission controller system)

Steering lock lever lock signal cannot be detected due to open circuit in lock detection pressure switch for steering lock lever. None in particular If cause of failure disappears, machine becomes normal by itself. Even if steering lock lever is set to LOCK position, steering can be operated. The input (ON/OFF) from the lock detection pressure switch for the steering lock lever can be checked by using the monitoring function (Code: 40908 D-IN-31). Method of reproducing failure code: Set the starting switch to ON position + Lock the steering lock lever Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector STL and connect T-adapter. 3. Start engine and perform troubleshooting. STL (male) Between (1) and (2) Steering lock lever LOCK Free Resistance Min. 1 Mz Max. 1 z

q q q q q

Defective lock detection pressure 1 switch for steering lock lever (Internal open circuit)

1. Prepare with starting switch at OFF position. Open circuit in wiring harness 2. Disconnect connectors L03, STL and connect T-adapter. 2 (wire breakage or defective con- 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L03 (female) (38) and STL tact of connector) Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, STL and connect T-adapter. Hot short circuit in wiring harness 3 3. Turn starting switch to ON position and perform troubleshooting. (contact with circuit) Between ground and wiring harness from L03 Voltage Max. 1 V (female) (38) to STL (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 4 Defective transmission controller L03 Between (38) and ground Steering lock lever LOCK Free Voltage 810 V Max. 1 V

40-278

WA1200-6

Troubleshooting by failure co Failure code [DDP5KA] Steering lock detector pressure switch signal circuit Disconnect

Related circuit diagram

40-279

WA1200-6

40-279

Troubleshooting by failure co Failure code [DDT4LD] T/M Cut Off set switch signal short circuit

Failure code [DDT4LD] T/M Cut Off set switch signal short circuit
Action level E01 Failure code DDT4LD Failure Transmission cut-off point set switch system error (open or short circuit) (Transmission controller system)

40-280

Detail of failure Ground fault has occurred in the cut-off point set switch circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S21 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Resistance S21 (male) Between (5) and (6) 15 Min. 25 z
q q

Cut-off point set switch: OFF Detail of failure is displayed in yellow on the multi-monitor screen.

Defective transmission cut-off point set switch

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, S21 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L04 2 Min. 1 Mz (contact with ground circuit) (female) (20) to S21 (female) (1) Resistance Between ground and wiring harness from L26 Min. 1 Mz (female) (15) to HR9 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Voltage L04 (female) 3 Defective transmission controller Max. 1 V Between (20) and ground Between (15) and ground Max. 1 V

Related circuit diagram

40-280

40-280

WA1200-6

Troubleshooting by failure co Failure code [DDT4LD] T/M Cut Off set switch signal short circuit

WA1200-6

40-281

Troubleshooting by failure co Failure code [DDW9LD] Kickdown Switch Short Circuit

Failure code [DDW9LD] Kickdown Switch Short Circuit

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-282

Failure code DDW9LD

Failure

Kick-down switch: switch is kept pressed for long time (Transmission controller system)

Due to ground fault in kickdown switch system, the kickdown signal is not turned off. Turns the kick-down ON when a grounding fault is detected, then do not control the kick-down any more. If cause of failure disappears, machine becomes normal by itself. When ground fault occurs, kick-down occurs once The input signal status (ON/OFF) from the kick-down switch can be checked by using the monitoring function (Code: 40906 D-IN-10). Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S07 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Kick-down S07 (male) Resistance switch Between (1) and (2) ON OFF Max. 1 z Min. 1 Mz

Defective kickdown switch (Internal short circuit)

Between (1), (2) and Ladder at any position Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, S07 and connect T-adapter. Ground fault in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (contact with ground circuit) Between ground and wiring harness from L04 Resistance Min. 1 Mz (female) (30) to S07 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Kick-down L04 Voltage 3 Defective transmission controller switch Between (30) and ground ON OFF Max. 1 V 810 V

40-282

WA1200-6

Troubleshooting by failure co Failure code [DDW9LD] Kickdown Switch Short Circuit

Related circuit diagram

40-283

WA1200-6

40-283

Troubleshooting by failure co Failure code [DGE5KX] Ambient air temp Sensor Failure

Failure code [DGE5KX] Ambient air temp Sensor Failure

Action level E01 Failure code DGE5KX Failure Ambient temperature sensor system error (KOMTRAX Plus controller system)

40-284

Detail of failure An error has occurred in the ambient temperature sensor circuit (input signal out of range) Action of controller
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Pm Clinic display becomes abnormal machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector PH1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. PH1 (male) Between (1) and (2) Ambient temperature Resistance Normal temperature Approx. 12 kz (25 C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2A to PH1 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V2A (female) (10) and Resistance Max. 1 z PH1 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2A to PH1 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.

Defective ambient temperature sensor

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Between ground and wiring harness from V2A Resistance Min. 1 Mz (female) (10) to PH1 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector V2A and connect T-adapter. Hot short circuit in wiring harness 4 3. Turn the starting switch to OFF position, then perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from V2A Voltage Max 1 V (female) (10) to PH1 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2A to PH1 in turn, and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective KOMTRAX Plus controlV2A Ambient temperature Resistance 5 ler 0 C Approx. 4 kz Between (10) and (13) 25 C Approx. 12 kz

Ground fault in wiring harness (Contact with ground circuit)

40-284

WA1200-6

Troubleshooting by failure co Failure code [DGE5KX] Ambient air temp Sensor Failure

Related circuit diagram

40-285

WA1200-6

40-285

Troubleshooting by failure co Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect

Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect

Action level E01
q

40-286

Failure code DGF1KA

Failure

Transmission oil temperature sensor: Open circuit (Transmission controller system)

Detail of failure Action of controller Problem on machine Related information

q q q q q q

Signal voltage from transmission oil temperature sensor is higher than normal range due to open circuit in transmission oil temperature sensor signal circuit. (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) Determines that transmission oil temperature is unusually low. If cause of failure disappears, machine becomes normal by itself. Gear shift shock may occur Input (temperature) from transmission oil temperature sensor can be checked by using monitoring function. (Code: 93600 T/M OIL TEMP) Input (voltage) from transmission oil temperature sensor can be checked by using monitoring function. (Code: 93601 T/M OIL TEMP) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

No.

1. Prepare with starting switch at OFF position. 2. Disconnect connectors T19, T25 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Defective transmission oil temper- Between T19 and T25 Transmission oil Resistance 1 ature sensor (internal open or (male) temperature short circuit) 25 C (normal tempera3550 kz ture) Between (1) and (2) 100 C 3.14.5 kz 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, T19, T25 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between L02 (female) (9) and T19 Resistance Max. 1 z tact of connector) (female) (1) Wiring harness between T25 (female) (1) and L02 Resistance Max. 1 z (female) (20) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Transmission oil L02 (female) Resistance 3 Defective transmission controller temperature 25 C (normal tempera3550 kz (9)(10) ture) (20)(10) 100 C 3.14.5 kz

40-286

WA1200-6

Troubleshooting by failure co Failure code [DGF1KA] Transmission Oil Temperature sensor signal Disconnect

Related circuit diagram

40-287

WA1200-6

40-287

Troubleshooting by failure co 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 level E01
q

Failure code DGF1KB

Failure

Transmission oil temperature sensor: short circuit (Transmission controller system)

Detail of failure Action of controller Problem on machine Related information

q q

Signal voltage from transmission oil temperature sensor is lower than normal range due to ground fault in transmission oil temperature sensor signal circuit. (Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150 C)) Determines that transmission oil temperature is unusually high. If cause of failure disappears, machine becomes normal by itself.

Gear shift shock may occur

q q q

Input (temperature) from transmission oil temperature sensor can be checked by using monitoring function. (Code: 93600 T/M OIL TEMP) Input (voltage) from transmission oil temperature sensor can be checked by using monitoring function. (Code: 93601 T/M OIL TEMP) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors T19, T25 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.

No.

Defective transmission oil temperature sensor (internal short circuit)

T19, T25 (male) Between (1) and (2)

Transmission oil temperature 25 C (normal temperature) 100 C

Resistance 3550 kz 3.14.5 kz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, T19, T25 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness 2 Between ground and wiring harness from L02 (contact with ground circuit) Min. 1 Mz (female) (9) to T19 (female) (1) Resistance Between ground and wiring harness from L02 Min. 1 Mz (female) (20) to T25 (female) (1) 1. Turn starting switch to OFF position. 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 (female) (9) to T19 (female) (1) Voltage Between ground and wiring harness from L02 Max. 1 V (female) (20) to T25 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 4 Defective transmission controller L02 (female) Between (9) and (21) Transmission oil temperature 25 C (normal temperature) 100 C Resistance 3550 kz 3.14.5 kz

40-288

WA1200-6

Troubleshooting by failure co Failure code [DGF1KB] Abnormality in Transmission Oil Temperature sensor Short Circuit

Related circuit diagram

40-289

WA1200-6

40-289

Troubleshooting by failure code Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)

Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)
WA1200-6

40-290

Action level E01

q

Failure code DGF1KX

Failure

Transmission oil temperature sensor: failure (for detection) (Transmission controller system)

Detail of failure Action of controller Problem on machine Related information No.

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 signal 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)). Controls clutch oil pressure while recognizing oil temperature as fixed high temperature Gear shift shocks will be larger This can be checked by using monitoring function (Code: 93600 ( C), 93601 (V)). After confirming that normal condition is recovered after repair work, perform the initial learning of the transmission controller, referring to Testing and adjusting, "Setting and adjusting of each equipment". Cause Procedure, measuring location, criteria and remarks 1. Turn starting switch to OFF position. 2. Disconnect connector T19. 3. Connect T-adapter Oil temperature: 25 C Between T19 (male) (1) Resistance Oil temperature: 100 C and (2) 1. Turn starting switch to OFF position. 2. Disconnect connectors L02, T19. 3. Connect T-adapter Wiring harness between L02 (female) (10) and T19 (female) (2) Resistance Wiring harness between L02 (female) (9) and T19 (female) (1) 1. Turn starting switch to OFF position. 2. Disconnect connectors L02, T19. 3. Connect T-adapter

q q q

Transmission oil temperature Defective sensor

3750 kz 3.54.0 kz

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Max. 1 z Max. 1 z

Between ground and wiring harness from L02 Resistance (female) (9) to T19 (female) (1) 1. Turn starting switch to OFF position. 2. Disconnect connectors L02, T19. Hot short circuit in wiring harness 3. Insert T-adapter 4 (contact with 24 V circuit) 4. Turn starting switch to ON position. Between ground and wiring harness from L02 Voltage (female) (9) to T19 (female) (1) 1. Turn starting switch to OFF position. 2. Disconnect connectors L02, T19. 3. Insert T-adapter 5 Defective transmission controller 4. Turn starting switch to ON position. Oil temperature: 25 C Between L02 (female) Resistance Oil temperature: 100 C (9) and (10)

Ground fault in wiring harness (contact with ground circuit)

Min. 1 Mz

Max 5 V

3750 kz 3.54.0 kz

40-290

WA1200-6

Troubleshooting by failure code Failure code [DGF1KX] Transmission Oil Temperature sensor Failure (For Check)

Related circuit diagram

40-291

WA1200-6

40-291

Troubleshooting by failure code Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure

Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure

Action level E01 Failure code DGH2KX Failure Hydraulic oil temperature sensor system error (Monitor panel controller system)

40-292

Detail of failure An error has occurred in the hydraulic oil temperature sensor circuit (input signal out of range) Action of controller
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Wrong alarm output machine Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HS1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HS1 (male) Between (1) and (2) Ground fault in wiring harness (Contact with ground circuit) Resistance 0.25 kz Resistance Approx. 37 50 kz

Defective hydraulic oil temperature sensor

3 Defective monitor panel controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, HSI and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC05 Resistance Min. 1 Mz (female) (7) to HSI (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. FC05 (female) Between (7) and ground Voltage Max. 1 V

Related electrical circuit diagram

40-292

40-292

WA1200-6

Troubleshooting by failure code Failure code [DGH2KX] Hydraulic oil temp. sensor circuit failure

WA1200-6

40-293

Troubleshooting by failure code Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection

Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection

Action level E01
q

40-294

Failure code DGR2KA

Failure

Rear brake oil temperature sensor: Open circuit (Machine monitor system)

Detail of failure Action of controller Problem on machine Related information

q q q

Signal voltage from rear brake oil temperature sensor is higher than normal range due to open or 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)) Takes it that the rear brake oil temperature is unusually low. Detail of failure is displayed in yellow on the multi-monitor screen. If cause of failure disappears, machine becomes normal by itself.

q q q

Input (temperature) from rear brake oil temperature sensor can be checked by using monitoring function. (Code: 30202 R BRAKE OIL) Input (voltage) from rear brake oil temperature sensor can be checked by using monitoring function. (Code: 30205 R BRAKE OIL) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HS6 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.

No.

Defective rear brake oil temperature sensor (internal open circuit)

HS6 (male) Between (1) and (2)

Hydraulic oil temperature 25 C (normal temperature) 100 C

Resistance 3550 kz 3.14.5 kz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, HS6 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between FC05 (female) (8) and Max. 1 z tact of connector) HS6 (female) (1) Resistance Wiring harness between HS6 (female) (2) and Max. 1 z ground 1. Turn starting switch to OFF position. 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 (female) (8) to HS6 (female) (1) Voltage Between ground and wiring harness from FC05 Max. 1 V (female) (11) to HS6 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 4 Defective machine monitor FC05 (female) Between (8) and ground Engine oil temperature 25 C (normal temperature) 100 C Resistance 3550 kz 3.14.5 kz

40-294

WA1200-6

Troubleshooting by failure code Failure code [DGR2KA] Brake oil temp. sensor circuit Disconnection

Related circuit diagram

40-295

WA1200-6

40-295

Troubleshooting by failure code Failure code [DGR2KX] Brake oil temp. sensor circuit failure

Failure code [DGR2KX] Brake oil temp. sensor circuit failure

Action level E01
q

40-296

Failure code DGR2KX

Failure

Rear brake oil temperature sensor: Input signal is out of normal range (Machine monitor system)

Detail of failure Action of controller Problem on machine Related information

q q

Signal voltage from rear brake oil temperature sensor is lower than normal range due to ground fault in rear brake oil temperature sensor signal circuit. (Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150 C)) Takes it that the rear brake oil temperature is unusually high. If cause of failure disappears, machine becomes normal by itself.

q q q

Input (temperature) from rear brake oil temperature sensor can be checked by using monitoring function. (Code: 30202 R BRAKE OIL) Input (voltage) from rear brake oil temperature sensor can be checked by using monitoring function. (Code: 30205 R BRAKE OIL) Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HS6 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.

No.

Defective rear brake oil temperature sensor (internal short circuit)

HS6 (male) Between (1) and ground

Hydraulic oil temperature 25 C (normal temperature) 100 C

Resistance 3550 kz 3.14.5 kz

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, HS6 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC05 Resistance Min. 1 Mz (female) (8) to HS6 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. FC05 (female) Between (8) and ground Engine oil temperature 25 C (normal temperature) 100 C Resistance 3550 kz 3.14.5 kz

3 Defective machine monitor

40-296

WA1200-6

Troubleshooting by failure code Failure code [DGR2KX] Brake oil temp. sensor circuit failure

Related circuit diagram

40-297

WA1200-6

40-297

Troubleshooting by failure code Failure code [DGT1KX] T/C oil temp. sensor circuit failure

Failure code [DGT1KX] T/C oil temp. sensor circuit failure

Action level E01 Failure code DGT1KX Failure Torque converter oil temperature sensor system error (Monitor panel controller system)

40-298

Detail of failure An error occurs in torque converter oil temperature sensor circuit (input signal out of range). Action of controller
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Problem on Wrong alarm output. machine Related information No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connector T24 and connect T-adapter. 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 Approx. 40 kz (25 C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from FC05 to T24 in turn, and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between FC05 Resistance Min. 1 Mz (female) (2) and T24 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between (1) and (2) FC05 (female) Between (2) and ground Resistance Min. 1 Mz

Ground fault in wiring harness (contact with ground circuit)

3 Defective monitor panel controller

Related circuit diagram

40-298

40-298

WA1200-6

Troubleshooting by failure code Failure code [DGT1KX] T/C oil temp. sensor circuit failure

WA1200-6

40-299

Troubleshooting by failure code Failure code [DH20KX] Torque converter pressure sensor circuit

Failure code [DH20KX] Torque converter pressure sensor circuit

Action level E01 Failure code DH20KX Failure Torque converter outlet pressure sensor system error (KOMTRAX Plus controller system)

40-30

Detail of failure An error has occurred in the torque converter outlet pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q

Detail of failure is displayed in yellow on the multi-monitor screen.

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). No. Cause Defective torque converter outlet pressure sensor (MT3) Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect sensor MT3 and replace with a normally operating sensor. 3. Turn starting switch to ON position and perform troubleshooting. Check if normal condition is recovered when torque converter outlet pressure sensor (MT3) is replaced with a normally operating sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors JT4 and JT5 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JT4 (male) (4) and (5) Between JT5 (male) (2) and (3) Resistance Max. 1 z Max. 1 z

Defective joint connector (JT4 or JT5)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to MT3 and from V2A to MT3 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness 3 (wire breakage or defective con- Wiring harness between V1 (female) (2) and MT3 Max. 1 z (female) (B) tact of connector) 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 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to MT3 and from V2A to MT3 in turn, and connect T-adapter. Ground fault in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 4 (Contact with ground circuit) Between ground and wiring harness from V1 Min. 1 Mz (female) (2) to MT3 (female) (B) Resistance Between ground and wiring harness from V2A Min. 1 Mz (female) (5) to MT3 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to MT3 in turn, and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn the starting switch to OFF position, then perform troubleshooting. 5 ler V1 (female), MT3 (female) Resistance Between V1 (2), MT3 (B) and ground Min. 1 Mz

40-300

WA1200-6

Troubleshooting by failure code Failure code [DH20KX] Torque converter pressure sensor circuit

Related circuit diagram

40-301

WA1200-6

40-301

Troubleshooting by failure code 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 level E01 Failure code DH21KA Failure Work equipment relief pressure sensor system error (Boom bucket & AJSS controller system)

Detail of failure An error has occurred in the work equipment relief pressure sensor circuit (input signal out of range) Action of controller Problem on machine Related information
q

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})

q

If failure code DHU3KX, DHU2KX, DHT8KX, or DHT4KX is issued at the same time, there is an open circuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 (female) (1). Work equipment relief pressure sensor voltage between HS2 (3) and (1): 0.7 - 5.3 V Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Replace sensor HS2 with a normally operating oil pressure sensor. 3. Turn starting switch to ON position and perform troubleshooting. Check if normal condition is recovered when work equipment relief pressure sensor (HS2) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors to L05 in turn Connect T-adapter to each connector to HS2. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (22) and HS2 Max. 1 z (female) (B) 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 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between L05 and HS2 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 Min. 1 Mz (female) (22) to HS2 (female) (B) Resistance Between ground and wiring harness from L05 Min. 1 Mz (female) (2) to HS2 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, HS2 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L05 (female), HS2 (female) Between L05 (22), HS2 (B) and ground Resistance Min. 1 Mz

No.

Defective work equipment relief pressure sensor (HS2)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

Defective boom bucket & AJSS controller

40-302

WA1200-6

Troubleshooting by failure code Failure code [DH21KA] Loader pump oil press sensor (Disconnect/Short Circuit)

Related circuit diagram

40-303

WA1200-6

40-303

Troubleshooting by failure code Failure code [DH21KB] Loader pump oil press sensor hot short

Failure code [DH21KB] Loader pump oil press sensor hot short
Action level E01 Failure code DH21KB Failure Work equipment relief pressure sensor system error (Boom bucket & AJSS controller system)

40-304

Detail of failure An error occurs in work equipment relief pressure sensor circuit (input signal out of range). Action of controller Problem on machine Related information
q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})

q

If failure codes DHU3KX, DHU2KX, DHT8KX, and DHT4KX occur at the same time, there is open circuit, defective contact, or ground fault in wiring harness between V1 (female) (2) and JR14 (female) (1). Work equipment relief pressure sensor voltage between HS2 (3) and (1): 0.7 to 5.3 V Cause Procedure, measuring location, criteria and remarks

No.

1. Prepare with starting switch at OFF position. 2. Replace sensor HS2 with a normally operating oil pressure sensor. Defective work equipment relief 1 3. Turn starting switch to ON position and perform troubleshooting. pressure sensor (HS2) Check if normal condition is recovered when work equipment relief pressure sensor (HS2) is replaced with normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 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) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, HS2 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Defective boom bucket & AJSS 3 controller L05 (female), HS2 (female) Resistance Between L05 (22), HS2 (B) and ground Min. 1 Mz

Related circuit diagram

40-304

40-304

WA1200-6

Troubleshooting by failure code Failure code [DH21KB] Loader pump oil press sensor hot short

WA1200-6

40-305

Troubleshooting by failure code Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)

Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)40-306

Action level E01 Failure code DHPCKA Failure Boom bottom pressure sensor system error (Boom bucket & AJSS controller system)

Detail of failure An error has occurred in the boom bottom pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Load meter reading is constantly 0 ton

Related infor- Boom bottom pressure sensor voltage mation q Between F06 (C) and (A): 0.7 - 5.3 V No. Cause Defective boom bottom pressure sensor (F06) Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T3 (1st solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Check if "DHPCKA" is displayed when wiring harness is replaced with that for boom head pressure sensor (F14) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector L04 and each connector to be disconnected to T3 in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JF4 (male) (1) and (7) Resistance Max. 1 z 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T3 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (14) and F06 Max. 1 z (female) (C) Resistance Wiring harness between F06 (female) (B) and FC01 Max. 1 z (female) (16) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T3 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L05 Resistance Min. 1 Mz (female) (14) to F06 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. q Between F06 (female) (B) and ground L05 (female) Between (14) and ground Resistance Max. 1 z

2 Defective joint connector (JF4)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

Defective boom bucket & AJSS controller

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WA1200-6

Troubleshooting by failure code Failure code [DHPCKA] Boom bottom press. (Disconnect/Short Circuit)

Related circuit diagram

40-307

WA1200-6

40-307

Troubleshooting by failure code Failure code [DHPCKX] Boom bottom press. sensor circuit failure

Failure code [DHPCKX] Boom bottom press. sensor circuit failure

Action level E01 Failure code DHPCKX Failure Boom bottom pressure sensor system error (Monitor panel controller system)

40-308

Detail of failure An error has occurred in the boom bottom pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Load meter reading is constantly 0 ton

Related infor- Boom bottom pressure sensor voltage mation q Between F06 (C) and (A): 0.7 - 5.3 V No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Replace wiring harness for pressure sensor F06 with wiring harness for pressure sensor F14 3. Turn starting switch to ON position and perform troubleshooting. Check if "DHPCKC" is displayed when wiring harness is replaced with that for boom head pressure sensor (F14) 1. Prepare with starting switch at OFF position. 2. Disconnect joint connector JF4 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JF4 (male) (1) and (7) Resistance Max. 1 z

Defective boom bottom pressure sensor (F06)

2 Defective joint connector (JF4)

1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connectors from FC01 to F06 in turn, and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 3 (wire breakage or defective conWiring harness between FC05 (female) (9) and F06 tact of connector) Max. 1 z (female) (C) Resistance Wiring harness between F06 (female) (B) and FC01 Max. 1 z (female) (16) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between FC05 and F06 in turn, and connect Ground fault in wiring harness T-adapter. 4 (Contact with ground circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC05 Resistance Min. 1 Mz (female) (9) to F06 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 5 Defective monitor panel controller q Between F06 (female) (B) and ground FC05 (female) Resistance Between (9) and ground Max. 1 z

40-308

WA1200-6

Troubleshooting by failure code Failure code [DHPCKX] Boom bottom press. sensor circuit failure

Related circuit diagram

40-309

WA1200-6

40-309

Troubleshooting by failure code Failure code [DHPCKY] Boom bottom press. hot short

Failure code [DHPCKY] Boom bottom press. hot short

Action level E01 Failure code DHPCKY Failure Boom bottom pressure sensor system error (Boom bucket & AJSS controller system)

40-310

Detail of failure An error has occurred in the boom bottom pressure sensor circuit (input signal out of range) Action of controller Problem on machine Load meter reading is constantly 0 ton

Related infor- Boom bottom pressure sensor voltage q Between F06 (C) and (A): 0.7 - 5.3 V mation No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Replace wiring harness for pressure sensor F06 with wiring harness for pressure sensor F14 3. Turn starting switch to ON position and perform troubleshooting. Check if "DHPCKY" is displayed when wiring harness is replaced with that for boom head pressure sensor (F14) 1. Prepare with starting switch at OFF position. 2. Disconnect joint connector JF4 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JF4 (male) (1) and (8) Resistance Max. 1 z

Defective boom bottom pressure sensor (F06)

2 Defective joint connector (JF3)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors between FC05 and F06 in turn, and connect Ground fault in wiring harness T-adapter. 3 (Contact with ground circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 Voltage Max. 1 V (female) (14) to F06 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 4 Defective monitor panel controller q Between F06 (female) (B) and ground L05 (female) Resistance Between (14) and ground Max. 1 z

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WA1200-6

Troubleshooting by failure code Failure code [DHPCKY] Boom bottom press. hot short

Related circuit diagram

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Troubleshooting by failure code Failure code [DHPDKX] Boom head press. sensor circuit failure

Failure code [DHPDKX] Boom head press. sensor circuit failure

Action level E01 Failure code DHPDKX Failure Boom head pressure sensor system error (Monitor panel controller system)

40-312

Detail of failure An error has occurred in the boom head pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Variation in accuracy will be large due to lever operation (back pressure cannot be corrected by boom head pressure)

Related infor- Boom head pressure sensor voltage mation q Between F14 (3) and (1): 0.7 - 5.3 V No. Cause Procedure, measuring location, criteria and remarks a Be ready with starting switch OFF, then turn starting switch to ON position and perform troubleshooting. Check if "DHPDKX" is displayed when wiring harness is replaced with that for boom bottom pressure sensor (F14) 1. Prepare with starting switch at OFF position. 2. Disconnect joint connector JF4 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JF4 (male) (1) and (8) Resistance Max. 1 z

Defective boom head pressure 1 sensor (F14)

2 Defective joint connector (JF4)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from FC05 to F14 and connectors from FC01 to F14 in turn, and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 3 (wire breakage or defective conWiring harness between FC05 (female) (4) and F14 tact of connector) Max. 1 z (female) (C) Resistance Wiring harness between F14 (female) (B) and FC01 Max. 1 z (female) (16) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between FC05 and F14 in turn, and connect Ground fault in wiring harness T-adapter. 4 (Contact with ground circuit) 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from FC05 Resistance Min. 1 Mz (female) (4) to F14 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 5 Defective monitor panel controller q Between F14 (female) (B) and ground FC05 (female) Resistance Between (6) and ground Max. 1 z

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Troubleshooting by failure code Failure code [DHPDKX] Boom head press. sensor circuit failure

Related circuit diagram

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40-313

Troubleshooting by failure code 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 level E01
q

Failure code DHT1KX

Failure

L.H. brake pressure sensor: Out of input signal range (Transmission controller system)

Detail of failure Action of controller

q q q

Due to ground fault in left brake pressure sensor signal system, the left brake pressure signal level is lower than normal range (Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min. 150 C)) Judged that left brake pressure is zero Detail of failure is displayed in yellow on the multi-monitor screen. If cause of failure disappears, machine becomes normal by itself.

Problem on machine Related inforq mation No.

Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L12 and connect T-adapter. Defective left brake pressure sen- 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L02 (female) (2) and L12 (female) (C) 1 sor (internal short circuit) Wiring harness between L02 (female) (16) and L12 (female) (B) Wiring harness between L02 (female) (4) and L12 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L12 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L02 Min. 1 Mz (female) (2) to L12 (female) (C) Resistance Between ground and wiring harness from L02 Min. 1 Mz (female) (16) to L12 (female) (B)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Resistance L02 (female) Between (16) and ground Min. 1 Mz

Related circuit diagram

40-314

40-314

WA1200-6

Troubleshooting by failure code Failure code [DHT1KX] T/M Cut Off pressure sensor signal Disconnect

WA1200-6

40-315

Troubleshooting by failure code Failure code [DHT2L6] T/M oil filter sensor circuit failure

Failure code [DHT2L6] T/M oil filter sensor circuit failure

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q

40-316

Failure code DHT2L6

Failure

Transmission oil filter clogging sensor: signal disagrees with run and stop of engine (machine monitor system)

Signal voltage from transmission oil filter clogging sensor disagrees with normal run and stop of engine due to failure in transmission oil filter clogging sensor signal circuit. If cause of failure disappears, machine becomes normal by itself. Transmission oil filter clogging caution lamp does not light up. Input (ON/OFF) from transmission oil filter clogging sensor can be checked by using monitoring function. (Code: 40903 D-IN-24) Method of reproducing failure code: Start the engine + Run the engine at full speed Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC03, FC04, R01, R02 and connect T-adapter. 3. Start engine and perform troubleshooting. R01, R02 (male) Between (1) and (2) Transmission oil filter Normal Clogging Resistance Max. 1 z Min. 1 Mz

q q q

Defective transmission oil filter 1 clogging sensor tor (internal open or short circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC03, FC04, R01, R02 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between FC03 (female) (5) and R02 Max. 1 z tact of connector) (female) (1) Resistance Wiring harness between FC04 (female) (5) and R01 Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC03, FC04, R01, R02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 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 Between ground and wiring harness from FC04 Min. 1 Mz (female) (5) to R01 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC03, FC04, R01, R02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 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 Between ground and wiring harness from FC04 Max. 1 V (female) (5) to R01 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC03, FC04 and connect T-adapter. 3. Start engine and perform troubleshooting. FC03 (female) Transmission oil Resistance FC04 (female) filter inlet pressure Between (5) and ground Normal Clogging Max. 1 z Min. 1 Mz

5 Defective machine monitor

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Troubleshooting by failure code Failure code [DHT2L6] T/M oil filter sensor circuit failure

Related circuit diagram

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40-317

Troubleshooting by failure code Failure code [DHT3KX] Transmission main pressure sensor circuit

Failure code [DHT3KX] Transmission main pressure sensor circuit

Action level E01 Failure code DHT3KX Failure Transmission main pressure sensor system error (KOMTRAX Plus controller system)

40-318

Detail of failure An error has occurred in the transmission main pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})

Related infor- If failure code DH20KX, 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). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect sensor MT2 and replace with a normally operating sensor. Defective transmission main relief 3. Turn starting switch to ON position and perform troubleshooting. 1 pressure sensor (MT2) Check if normal condition is recovered when transmission main relief pressure sensor (MT2) is replaced with a normally operating sensor 1. Prepare with starting switch at OFF position. 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 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to MT2 and from V2A to MT2 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness Wiring harness between V1 (female) (2) and MT2 3 (wire breakage or defective conMax. 1 z (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 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to MT2 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness 4 Between ground and wiring harness from V1 (Contact with ground circuit) Min. 1 Mz (female) (2) to MT2 (female) (B) Resistance Between ground and wiring harness from V2A Min. 1 Mz (female) (6) to MT2 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and MT2 and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn the starting switch to OFF position, then perform troubleshooting. 5 ler V1 (female), MT2 (female) Resistance Between V1 (2), MT2 (B) and ground Min. 1 Mz

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WA1200-6

Troubleshooting by failure code Failure code [DHT3KX] Transmission main pressure sensor circuit

Related circuit diagram

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WA1200-6

40-319

Troubleshooting by failure code Failure code [DHT4KX] Main PPC oil pressure sensor circuit

Failure code [DHT4KX] Main PPC oil pressure sensor circuit

Action level E01 Failure code DHT4KX Failure Main PPC oil pressure sensor system error (KOMTRAX Plus controller system)

40-320

Detail of failure An error has occurred in the main PPC oil pressure sensor circuit (input signal out of range) Action of controller 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 inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect sensor HS4 and replace with a normally operating sensor. Defective PPC oil pressure sensor 1 3. Turn starting switch to ON position and perform troubleshooting. (HS4) Check if normal condition is recovered when PPC oil pressure sensor (HS4) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors JR13 and JR14 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Defective joint connector (JL2, 2 JR7, or JR14) Between JR13 (male) (1) and (6) Max. 1 z Resistance Between JR14 (male) (1) and (2) Max. 1 z 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to HS4 and from V2A to HS4 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (2) and HS4 Max. 1 z (female) (B) Wiring harness between V2A (female) (1) and HS4 Resistance Max. 1 z (female) (C) Wiring harness between HS4 (female) (A) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to HS4 and from V2A to HS4 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V1 (female) (2) to HS4 (female) (B) Between ground and wiring harness from V2A (female) (1) to HS4 (female) (C) Min. 1 Mz Resistance Min. 1 Mz

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and HS4 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. V1 (female), HS4 (female) 5 Resistance Min. 1 Mz Defective KOMTRAX Plus control- Between V1 (2), HS4 (B) and ground ler 1. Prepare with starting switch at OFF position. 2. Disconnect connector V2A and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. V2A Between (1) and (12) Voltage 0.7 5.3 V

40-320

WA1200-6

Troubleshooting by failure code Failure code [DHT4KX] Main PPC oil pressure sensor circuit

Related circuit diagram

40-321

WA1200-6

40-321

Troubleshooting by failure code Failure code [DHT5KX] Torque converter intake pressure sensor circuit

Failure code [DHT5KX] Torque converter intake pressure sensor circuit40-32

Action level E01 Failure code DHT5KX Failure Torque converter inlet oil pressure sensor system error (KOMTRAX Plus controller system)

An error has occurred in the torque converter inlet oil pressure sensor circuit (input signal out of Detail of failure range) Action of conq Detail of failure is displayed in yellow on the multi-monitor screen. troller Problem on machine Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})

Related infor- If failure code DHT3KX, DH20KX, or DHT9KX 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). No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect sensor HS4 and replace with a normally operating sensor. 3. Turn starting switch to ON position and perform troubleshooting. Check if normal condition is recovered when torque converter inlet pressure sensor (MT4) is replaced with a normally operating sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors JT4 and JT5 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JT4 (male) (2) and (6) Between JT5 (male) (1) and (4) Resistance Max. 1 z Max. 1 z

Defective torque converter inlet pressure sensor (MT4)

Defective joint connector (JT4 or JT5)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to MT4 and from V2B to MT4 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (2) and MT4 Max. 1 z (female) (B) Wiring harness between V2B (female) (10) and Resistance Max. 1 z MT4 (female) (C) Wiring harness between MT4 (female) (A) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to MT4 and from V2B to MT4 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V1 (female) (2) to MT4 (female) (B) Between ground and wiring harness from V2B (female) (10) to MT4 (female) (C) Min. 1 Mz Resistance Min. 1 Mz

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Troubleshooting by failure code Failure code [DHT5KX] Torque converter intake pressure sensor circuit

No.

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and MT4 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. V1 (female), MT4 (female) Resistance

Min. 1 Mz Defective KOMTRAX Plus control- Between V1 (2), MT4 (B) and ground ler 1. Prepare with starting switch at OFF position. 2. Disconnect connector V2B and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. V2B Between (10) and (12) Voltage 0.7 5.3 V

Related circuit diagram

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WA1200-6

40-323

Troubleshooting by failure code Failure code [DHT8KX] Steering Oil Press. Sensor Failure

Failure code [DHT8KX] Steering Oil Press. Sensor Failure

Action level E01 Failure code DHT8KX Failure Steering oil pressure sensor system error (KOMTRAX Plus controller system)

40-324

Detail of failure An error has occurred in the steering oil pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})

If failure code DHU3KX, DH24KX, DHU2KX, or DHT4KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect sensor HS3 and replace with a normally operating sensor. 3. Turn starting switch to ON position and perform troubleshooting. Check if normal condition is recovered when steering relief oil pressure sensor (HS3) is replaced with a normally operating oil pressure sensor

Defective steering relief oil pressure sensor (HS3)

1. Prepare with starting switch at OFF position. 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 Between JR14 (male) (1) and (4) Max. 1 z 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to HS3 and from V2A to HS3 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (2) and HS3 Max. 1 z (female) (B) Wiring harness between V2A (female) (16) and Resistance Max. 1 z HS3 (female) (C) Wiring harness between HS3 (female) (A) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V1 to HS3 and from V2A to HS3 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V1 (female) (2) to HS3 (female) (B) Between ground and wiring harness from V2A (female) (16) to HS3 (female) (C) Min. 1 Mz Resistance Min. 1 Mz

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

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Troubleshooting by failure code Failure code [DHT8KX] Steering Oil Press. Sensor Failure

No.

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and HS3 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. V1 (female), HS3 (female) Resistance

Min. 1 Mz Defective KOMTRAX Plus control- Between V1 (2), HS3 (B) and ground ler 1. Prepare with starting switch at OFF position. 2. Disconnect connector V2A and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. V2A Between (6) and (13) Voltage 0.7 5.3 V

Related circuit diagram

40-325

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40-325

Troubleshooting by failure code Failure code [DHTAKX] Transmission lubrication pressure sensor circuit

Failure code [DHTAKX] Transmission lubrication pressure sensor circuit40-326

Action level E01 Failure code DHTAKX Failure Transmission lubricating oil pressure sensor system error (KOMTRAX Plus controller system)

An error has occurred in the transmission lubricating oil pressure sensor circuit (input signal out of Detail of failure range) Action of conq Detail of failure is displayed in yellow on the multi-monitor screen. troller Problem on Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2}) machine Related information No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect sensor MT1 and replace with a normally operating sensor. 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 pressure sensor (MT1) is replaced with a normally operating sensor Defective joint connector 2 (JL11 or JT3) 1. Prepare with starting switch at OFF position. 2. Disconnect connector JT3 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JT3 (male) (1) and (6) Resistance Max. 1 z

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from V2B to MT1 in turn, and connect T-adapter. Hot short circuit in wiring harness 3. Turn starting switch to ON position and perform troubleshooting. 3 (contact with 24 V circuit) Between ground and wiring harness from V2B Voltage Max. 1 V (female) (4) to MT1 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and MT1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. V1 (female), MT1 (female) 4 Resistance Between V1 (4), MT1 (B) and ground Min. 1 Mz Defective KOMTRAX Plus control1. Prepare with starting switch at OFF position. ler 2. Disconnect connector V2B and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. V2B (4) Voltage 0.7 5.3 V

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Troubleshooting by failure code Failure code [DHTAKX] Transmission lubrication pressure sensor circuit

Related circuit diagram

40-327

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40-327

Troubleshooting by failure code Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect

Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect

Action level E03 Detail of failure Action of controller Problem on machine Failure code DHTBKA Failure Transmission modulation oil pressure sensor system error (Transmission controller system)

40-328

An error has occurred in the transmission modulation oil pressure sensor circuit (input signal out of range)
q

Turns the centralized warning lamp and alarm buzzer ON.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})

If failure code DH24KX, DHU2KX, DHT8KX, or DHT4KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JT2 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect sensor MT5 and replace with a normally operating sensor. Defective transmission modulation 3. Turn starting switch to ON position and perform troubleshooting. 1 oil pressure sensor (MT5) Check if normal condition is recovered when transmission modulation oil pressure sensor (MT5) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L02 to MT5 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L02 (female) (16) and MT5 Max. 1 z (female) (B) 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 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L02 to MT5 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L02 (female) (16) to MT5 (female) (B) Between ground and wiring harness from L02 (female) (15) to MT5 (female) (3) Min. 1 Mz Resistance Min. 1 Mz

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02 and MT5 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L02 (female), MT5 (female) 4 Defective transmission controller Resistance Between L02 (16), MT5 (B) and Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 Between (4) and (8) Voltage 0.7 5.3 V

40-328

WA1200-6

Troubleshooting by failure code Failure code [DHTBKA] Modulation clutch pressure sensor circuit Disconnect

Related circuit diagram

40-329

WA1200-6

40-329

Troubleshooting by failure code Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit

Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit 40-3 0
Action level E03 Detail of failure Action of controller Problem on machine Failure code DHTBKB Failure Transmission modulation oil pressure sensor system error (Transmission controller system)

An error has occurred in the transmission modulation oil pressure sensor circuit (input signal out of range)
q

Turns the centralized warning lamp and alarm buzzer ON.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2})

If failure code DH24KX, DHU2KX, DHT8KX, or DHT4KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JT2 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect sensor MT5 and replace with a normally operating sensor. Defective transmission modulation 3. Turn starting switch to ON position and perform troubleshooting. 1 oil pressure sensor (MT5) Check if normal condition is recovered when transmission modulation oil pressure sensor (MT5) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L02 to MT5 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 2 Ground fault in wiring harness (Contact with ground circuit) Between ground and wiring harness from L02 (female) (16) to MT5 (female) (B) Between ground and wiring harness from L02 (female) (8) to MT5 (female) (C) Max. 1 V Voltage Max. 1 V

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02 and MT5 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L02 (female), MT5 (female) 3 Defective transmission controller Resistance Between L02 (16), MT5 (B) and Min. 1 Mz ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 Between (4) and (8) Voltage 0.7 5.3 V

Related circuit diagram

40-3 0

40-330

WA1200-6

Troubleshooting by failure code Failure code [DHTBKB] Modulation clutch pressure sensor signal short circuit

WA1200-6

40-331

Troubleshooting by failure code Failure code [DHU2KA] F Brake Oil press Sensor Disconnect

Failure code [DHU2KA] F Brake Oil press Sensor Disconnect

Action level E01 Failure code DHU2KA Failure Front brake oil pressure sensor system error (Transmission controller system)

40-3 2

Detail of failure An error has occurred in the front brake oil pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2}) q Alarm false detected If failure code DHU3KX, DH24KX, DHT8KX, or DHT4KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 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 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to HR20 and from L02 to HR20 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (34) and Max. 1 z HR20 (female) (B) Wiring harness between L02 (female) (24) and Resistance Max. 1 z HR20 (female) (C) Wiring harness between HR20 (female) (C) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to HR20 and from L02 to HR20 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L04 (female) (34) to HR20 (female) (B) Between ground and wiring harness from L02 (female) (24) to HR20 (female) (C) Min. 1 Mz Resistance Min. 1 Mz

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

4 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02 and HR20 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L04 (female), HR20 (female) Between L04 (34), HR20 (B) and ground Resistance Min. 1 Mz

40-332

WA1200-6

Troubleshooting by failure code Failure code [DHU2KA] F Brake Oil press Sensor Disconnect

Related circuit diagram

40-3 3

WA1200-6

40-333

Troubleshooting by failure code Failure code [DHU2KB] F Brake Oil press Sensor Hot short

Failure code [DHU2KB] F Brake Oil press Sensor Hot short

Action level E01 Failure code DHU2KB Failure Front brake oil pressure sensor system error (Transmission controller system)

40-3 4

Detail of failure An error has occurred in the front brake oil pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2}) q Alarm false detected If failure code DHU3KX, DH24KX, DHT8KX, or DHT4KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Replace oil pressure sensor HR20 with a normally operating oil pressure sensor Defective front brake oil pressure 1 3. Turn starting switch to ON position and perform troubleshooting. sensor (HR20) Check if normal condition is recovered when front brake oil pressure sensor (HR20) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between L02 and HR20 in turn and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with +5 V circuit) Between ground and wiring harness from L02 Voltage Max. 1 V (female) (24) to HR20 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04 and HR20 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 3 Defective transmission controller L04 (female), HR20 (female) Resistance Between L04 (34), HR20 (B) and ground Min. 1 Mz

Related circuit diagram

40-3 4

40-334

WA1200-6

Troubleshooting by failure code Failure code [DHU2KB] F Brake Oil press Sensor Hot short

WA1200-6

40-335

Troubleshooting by failure code Failure code [DHU2KX] F Brake Oil press Sensor Failure

Failure code [DHU2KX] F Brake Oil press Sensor Failure

Action level E01 Failure code DHU2KX Failure Front brake oil pressure sensor system error (KOMTRAX Plus controller system)

40-3 6

Detail of failure An error has occurred in the front brake oil pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2}) q Alarm false detected If failure code DHU3KX, DH24KX, DHT8KX, or DHT4KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Replace oil pressure sensor HR15 with a normally operating oil pressure sensor Defective front brake oil pressure 1 3. Turn starting switch to ON position and perform troubleshooting. sensor (HR15) Check if normal condition is recovered when front brake oil pressure sensor (HR15) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect joint connectors JR13, JR14 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JR13 (male) (1) and (3) Between JR14 (male) (1) and (5) Resistance Max. 1 z Max. 1 z

Defective joint connector (JR13 or JR14)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connectors from V1 to HR15 and from V2A to HR15 in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (2) and HR15 Max. 1 z (female) (B) 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 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and V2A to HR15 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V1 (female) (2) to HR15 (female) (B) Between ground and wiring harness from V2A (female) (7) to HR15 (female) (C) Min. 1 Mz Resistance Min. 1 Mz

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and HR15 and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn the starting switch to OFF position, then perform troubleshooting. 5 ler V1 (female), HR15 (female) Resistance Between V1 (2), HR15 (B) and ground Min. 1 Mz

40-336

WA1200-6

Troubleshooting by failure code Failure code [DHU2KX] F Brake Oil press Sensor Failure

Related circuit diagram

40-3 7

WA1200-6

40-337

Troubleshooting by failure code Failure code [DHU3KA] R Brake Oil press Sensor Disconnect

Failure code [DHU3KA] R Brake Oil press Sensor Disconnect

Action level E01 Failure code DHU3KA Failure Rear brake oil pressure sensor system error (Transmission controller system)

40-3 8

Detail of failure An error has occurred in the rear brake oil pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2}) q Alarm false detected If failure code DH24KX, DHU2KX, DHT8KX, or DH20KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Replace oil pressure sensor HR21 with a normally operating sensor 3. Turn starting switch to ON position and perform troubleshooting. Check if normal condition is recovered when rear brake oil pressure sensor (HR21) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connectors from L04 to HR21 and from L02 to HR21 in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (34) and Max. 1 z HR21 (female) (B) Wiring harness between L02 (female) (18) and Resistance Max. 1 z HR21 (female) (C) Wiring harness between HR21 (female) (A) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to HR20 and from L02 to HR20 in turn, and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L04 (female) (34) to HR21 (female) (B) Between ground and wiring harness from L02 (female) (18) to HR21 (female) (C) Min. 1 Mz Resistance Min. 1 Mz

Defective rear brake oil pressure sensor (HR21)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

4 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02 and HR21 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L04 (female), HR21 (female) Between L04 (34), HR21 (B) and ground Resistance Min. 1 Mz

40-338

WA1200-6

Troubleshooting by failure code Failure code [DHU3KA] R Brake Oil press Sensor Disconnect

Related circuit diagram

40-3 9

WA1200-6

40-339

Troubleshooting by failure code Failure code [DHU3KB] R Brake Oil press Sensor Hot short

Failure code [DHU3KB] R Brake Oil press Sensor Hot short

Troubleshooting by failure code 40-340 WA1200-6

40-340

Action level E01

Failure code DHU3KB

Failure

Rear brake oil pressure sensor system error (Transmission controller system)

Detail of failure An error has occurred in the rear brake oil pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2}) q Alarm false detected If failure code DH24KX, DHU2KX, DHT8KX, or DH20KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Replace oil pressure sensor HR21 with a normally operating oil pressure sensor Defective rear brake oil pressure 1 3. Turn starting switch to ON position and perform troubleshooting. sensor (HR21) Check if normal condition is recovered when rear brake oil pressure sensor (HR21) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors between L02 and HR21 in turn and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with +5 V circuit) Between ground and wiring harness from L02 Voltage Max. 1 V (female) (18) to HR21 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04 and HR21 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 3 Defective transmission controller L04 (female), HR21 (female) Resistance Between L04 (34), HR21 (B) and ground Min. 1 Mz

Related circuit diagram

40-340

40-340

WA1200-6

Troubleshooting by failure code Failure code [DHU3KX] R Brake Oil press Sensor Failure

Failure code [DHU3KX] R Brake Oil press Sensor Failure

Action level E01 Failure code DHU3KX Failure Rear brake oil pressure sensor system error (KOMTRAX Plus controller system)

40-341

Detail of failure An error has occurred in the rear brake oil pressure sensor circuit (input signal out of range) Action of controller Problem on machine
q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Real-time monitor display: constantly detects minimum pressure (0 MPa {0 kg/cm2}) q Alarm false detected If failure code DH24KX, DHU2KX, DHT8KX, or DH20KX is issued at the same time, there is an open Related inforcircuit, defective contact, or ground fault in the wiring harness between V1 (female) (2) and JR14 mation (female) (1). No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Replace oil pressure sensor HR16 with a normally operating oil pressure sensor 3. Turn starting switch to ON position and perform troubleshooting. Check if normal condition is recovered when rear brake oil pressure sensor (HR16) is replaced with a normally operating oil pressure sensor 1. Prepare with starting switch at OFF position. 2. Disconnect joint connectors JR13, JR14 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between JR13 (male) (1) and (4) Between JR14 (male) (1) and (6) Resistance Max. 1 z Max. 1 z

Defective rear brake oil pressure sensor (HR16)

Defective joint connector (JR13 or JR14)

Open circuit in wiring harness 3 (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connectors from V1 to HR16 and from V2A to HR16 in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between V1 (female) (2) and HR16 Max. 1 z (female) (B) Wiring harness between V2A (female) (8) and Resistance Max. 1 z HR16 (female) (C) Wiring harness between HR16 (female) (A) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1 and V2A to HR21 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from V1 (female) (2) to HR16 (female) (B) Between ground and wiring harness from V2A (female) (8) to HR16 (female) (C) Min. 1 Mz Resistance Min. 1 Mz

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04 and HR21 and connect T-adapter. Defective KOMTRAX Plus control- 3. Turn the starting switch to OFF position, then perform troubleshooting. 5 ler V1 (female), HR16 (female) Resistance Between V1 (2), HR16 (B) and ground Min. 1 Mz

WA1200-6

40-341

Troubleshooting by failure code Failure code [DHU3KX] R Brake Oil press Sensor Failure

Related circuit diagram

40-342

40-342

WA1200-6

Troubleshooting by failure code Failure code [DJF1KA] Fuel level sensor circuit Disconnection

Failure code [DJF1KA] Fuel level sensor circuit Disconnection

Action level E01 Failure code DJF1KA Failure Fuel level sensor system error (input signal out of range) (Monitor panel controller system)

40-343

Detail of failure Open circuit or hot short circuit has occurred in fuel level sensor circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector R05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 1 Defective fuel level sensor R05 (male) Between (1) and (3) Between (1) and (2) Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Resistance 0.25 kz 05 kz
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, R05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between FC05 (female) (1) and R05 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, R05 and connect T-adapter. Hot short circuit in wiring harness 3 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness from FC05 Voltage Max. 1 V (female) (1) to R05 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 4 Defective monitor panel controller FC05 (female) Voltage (1)(11) 4.95.1 V

Related circuit diagram

40-343

WA1200-6

40-343

Troubleshooting by failure code Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit)

Failure code [DK30KA] Steering lever angle sensor (Disconnect/Short Circuit) 40-34
Action level E01 Failure code DK30KA Failure AJSS/T lever system error (input signal out of range) (Boom bucket & AJSS controller system)

Detail of failure Open circuit or ground fault has occurred in the boom angle circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector R33 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. R33 (male) Between (1) and ground Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Resistance Min. 1 Mz
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1 Defective potentiometer

Ground fault in wiring harness (Contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, R33 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (26) to R33 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, R33 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Resistance Min. 1 Mz (female) (26) to R33 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) Between (26) and ground Resistance Min. 1 Mz

Related circuit diagram

40-34

40-344

WA1200-6

Troubleshooting by failure code Failure code [DK30KY] Steering lever angle sensor circuit hot short

Failure code [DK30KY] Steering lever angle sensor circuit hot short
Action level E01 Failure code DK30KY Failure AJSS/T lever system error (input signal out of range) (Boom bucket & AJSS controller system)

40-345

Detail of failure Hot short circuit has occurred in the boom lever potentiometer circuit Action of controller Problem on machine
q q

Steering source pressure control EPC solenoid output: OFF Control the frame angle sensor signal voltage as the input voltage.

Effective steering speed is different to the right and left.

a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector R33 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. R33 (male) Between (1) and ground Resistance Min. 1 Mz

1 Defective potentiometer

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, R33 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness from L07 Voltage Max. 1 V (female) (26) to R33 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Resistance Between (26) and ground Min. 1 Mz

Related circuit diagram

40-345

WA1200-6

40-345

Troubleshooting by failure code Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)

Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)

Action level E03 Failure code DK59KA Failure Frame angle sensor system error (input signal out of range) (Boom bucket & AJSS controller system)

40-346

Detail of failure Open circuit or ground fault has occurred in the boom lever potentiometer circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S03 (male) Between (3) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective boom lever potentiometer

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (19) and S03 Max. 1 z (female) (3) Resistance Wiring harness between L05 (female) (22) and S03 Max. 1 z (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 (female) (19) to S03 (female) (3) Between ground and wiring harness from L05 (female) (22) to S03 (female) (4) Min. 1 Mz Resistance Min. 1 Mz

Ground fault in wiring harness (Contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) Between (22) and ground Voltage 4.95.1 V

40-346

WA1200-6

Troubleshooting by failure code Failure code [DK59KA] Boom lever potentiometer (main) (Disconnect/Short Circuit)

Related circuit diagram

40-347

WA1200-6

40-347

Troubleshooting by failure code Failure code [DK59KY] Boom lever potentiometer (main) hot short

Failure code [DK59KY] Boom lever potentiometer (main) hot short

Action level E03 Failure code DK59KY Failure Boom lever potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

40-348

Detail of failure Open circuit or ground fault has occurred in the boom lever potentiometer circuit Action of controller Problem on machine a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S03 (male) Between (3) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective boom lever potentiometer

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with +5 V circuit) Between ground and wiring harness from L05 Voltage Max. 1 V (female) (19) to S03 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L05 (female) Voltage Between (22) and ground 4.95.1 V

Related circuit diagram

40-348

40-348

WA1200-6

Troubleshooting by failure code Failure code [DK59L8] Boom lever potentiometer (main & sub) failure

Failure code [DK59L8] Boom lever potentiometer (main & sub) failure 40-349
Action level E03
q

Failure code DK59L8

Failure

Bucket EPC lever potentiometer (Main): system error (Boom bucket & AJSS controller system)

Detail of failure
q q

Action of controller

q q q q

Problem on machine

q q q

Related information

q q

Bucket EPC lever potentiometer (Main & Sub) input signals disagree with each other. (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) Cannot recognize the bucket EPC lever position correctly. Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality 5%, as the regular potentiometer. Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neutrality 5%. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until bucket EPC lever is set to N (NEUTRAL). Bucket moves with bucket control lever in NEUTRAL. If either the main potentiometer or the subpotentiometer malfunctions, the machine operates normally after the lever is set to neutral. If both the main potentiometer and subpotentiometer malfunction, the bucket does not move. The input condition (voltage) from the bucket EPC lever potentiometer (main) can be checked with the monitoring function (code: 42002 BUCKET POT1). The input condition (voltage) from the bucket EPC lever potentiometer (sub) can be checked with the monitoring function (code: 42003 BUCKET POT2). Method of reproducing failure code: Starting switch ON and operate bucket lever Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S03 (male) Between (1) and (4) Between (1), (2), (3), (4) and ground Resistance 3.2 0.64 kz Min. 1 Mz

No.

1. Prepare with starting switch at OFF position. 2. Disconnect connector S03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. S03 Between (4) and (1) Defective bucket EPC lever poten1 tiometer tor (internal open or short circuit) Between (3) and (1) Bucket EPC lever Ladder at any position Set lever to NEUTRAL. Move to TILT (before detent) Move to TILT (detent position) Full DUMP operation Set lever to NEUTRAL. Move to TILT (before detent) Between (2) and (1) Move to TILT (detent position) Full DUMP operation Voltage 4.85 to 5.15 V 2.402.60 V 3.644.14 V 3.864.36 V 0.641.14 V 2.402.60 V 0.861.36 V 0.641.14 V 3.864.36 V

WA1200-6

40-349

Troubleshooting by failure code Failure code [DK59L8] Boom lever potentiometer (main & sub) failure

No.

Cause

Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (13) and S03 Max. 1 z (female) (2) Open circuit in wiring harness 2 Wiring harness between L05 (female) (19) and S03 (open circuit or defective contact) Max. 1 z (female) (3) Resistance Wiring harness between L05 (female) (10) and S03 Max. 1 z (female) (1) Wiring harness between L05 (female) (22) and S03 Max. 1 z (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 Min. 1 Mz (female) (13) to S03 (female) (2) Ground fault in wiring harness 3 Between ground and wiring harness from L05 (contact with ground circuit) (female) (19) to S03 (female) (3) Resistance Min. 1 Mz Between ground and wiring harness from L05 (female) (22) to S03 (female) (4), and to circuit Min. 1 Mz branch end 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L05 Max. 1 V Hot short circuit in wiring harness (female) (13) to S03 (female) (2) 4 Between ground and wiring harness from L05 (contact with 24 V circuit) Max. 1 V (female) (19) to S03 (female) (3) Voltage Between ground and wiring harness from L05 (female) (22) to S03 (female) (4), and to circuit Max. 1 V branch end 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 Between (22) and (10) Bucket EPC lever Ladder at any position Set lever to NEUTRAL. Move to TILT (before detent) Move to TILT (detent position) Full DUMP operation Set lever to NEUTRAL. Move to TILT (before detent) Move to TILT (detent position) Full DUMP operation Voltage 4.85 to 5.15 V 2.402.60 V 3.644.14 V 3.864.36 V 0.641.14 V 2.402.60 V 0.861.36 V 0.611.14 V 3.964.36 V

Defective work equipment controller

Between (19) and (10)

Between (13) and (10)

40-350

WA1200-6

Troubleshooting by failure code Failure code [DK59L8] Boom lever potentiometer (main & sub) failure

Related circuit diagram

40-351

WA1200-6

40-351

Troubleshooting by failure code Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)

Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)

Action level E03 Failure code DK5AKA Failure Boom lever potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

40-352

Detail of failure Open circuit or ground fault has occurred in the boom lever potentiometer circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S03 (male) Between (2) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective boom lever potentiometer

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (13) and S03 Max. 1 z (female) (2) Resistance Wiring harness between L05 (female) (22) and S03 Max. 1 z (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 (female) (13) to S03 (female) (2) Between ground and wiring harness from L05 (female) (22) to S03 (female) (4) Min. 1 Mz Resistance Min. 1 Mz

Ground fault in wiring harness (Contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) Between (22) and ground Voltage 4.95.1 V

40-352

WA1200-6

Troubleshooting by failure code Failure code [DK5AKA] Boom lever potentiometer (sub) (Disconnect/Short Circuit)

Related circuit diagram

40-353

WA1200-6

40-353

Troubleshooting by failure code Failure code [DK5AKY] Boom lever potentiometer (sub) hot short

Failure code [DK5AKY] Boom lever potentiometer (sub) hot short

Action level E03 Failure code DK5AKY Failure Boom lever potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

40-354

Detail of failure Open circuit or ground fault has occurred in the boom lever potentiometer circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S03 (male) Between (2) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective boom lever potentiometer

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S03 and connect T-adapter. Hot short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (contact with +5 V circuit) Between ground and wiring harness from L05 Resistance Min. 1 Mz (female) (13) to S03 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L05 (female) Voltage Between (22) and ground 4.95.1 V

Related circuit diagram

40-354

40-354

WA1200-6

Troubleshooting by failure code Failure code [DK5AKY] Boom lever potentiometer (sub) hot short

WA1200-6

40-355

Troubleshooting by failure code Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)

Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)

Action level E03 Failure code DK5BKA Failure Bucket lever potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

40-356

Detail of failure Open circuit or ground fault has occurred in the bucket lever potentiometer circuit Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Dumps momentarily but then operates normally, controlled by sub potentiometer a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S02 (male) Between (3) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz

Defective bucket lever potentiometer

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (7) and S02 Max. 1 z (female) (3) Resistance Wiring harness between L05 (female) (22) and S02 Max. 1 z (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 (female) (7) to S02 (female) (3) Between ground and wiring harness from L05 (female) (22) to S02 (female) (4) Min. 1 Mz Resistance Min. 1 Mz

Ground fault in wiring harness (Contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) Between (22) and ground Voltage 4.95.1 V

40-356

WA1200-6

Troubleshooting by failure code Failure code [DK5BKA] Bucket lever potentiometer (main) (Disconnect/Short Circuit)

Related circuit diagram

40-357

WA1200-6

40-357

Troubleshooting by failure code Failure code [DK5BKY] Bucket lever potentiometer (main) hot short

Failure code [DK5BKY] Bucket lever potentiometer (main) hot short

Action level E03 Failure code DK5BKY Failure Bucket lever potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

40-358

Detail of failure Open circuit or ground fault has occurred in the bucket lever potentiometer circuit Action of controller Problem on machine
q

Turns the centralized warning lamp and alarm buzzer ON.

Tilts momentarily but then operates normally, controlled by sub potentiometer

a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S02 (male) Between (3) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz

Defective bucket lever potentiometer

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. Hot short circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (contact with +5 V circuit) Between ground and wiring harness from L05 Resistance Min. 1 Mz (female) (7) to S02 (female) (3) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L05 (female) Voltage Between (22) and ground 4.95.1 V

Related circuit diagram

40-358

40-358

WA1200-6

Troubleshooting by failure code Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure

Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure 40-359
Action level E03
q

Failure code DK5BL8

Failure

Bucket EPC lever potentiometer (Main): system error (Boom bucket & AJSS controller system)

Detail of failure
q q

Action of controller

q q q q

Problem on machine

q q q

Related information

q q

Bucket EPC lever potentiometer (Main & Sub) input signals disagree with each other. (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) Cannot recognize the bucket EPC lever position correctly. Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality 5 %, as the regular potentiometer. Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neutrality 5 %. Turns the centralized warning lamp and alarm buzzer ON. Even if cause of failure disappears, machine does not become normal until bucket EPC lever is set to N (NEUTRAL). Bucket moves with bucket control lever in NEUTRAL. If either the main potentiometer or the subpotentiometer malfunctions, the machine operates normally after the lever is set to neutral. If both the main potentiometer and subpotentiometer malfunction, the bucket does not move. The input condition (voltage) from the bucket EPC lever potentiometer (main) can be checked with the monitoring function (code: 42002 BUCKET POT1). The input condition (voltage) from the bucket EPC lever potentiometer (sub) can be checked with the monitoring function (code: 42003 BUCKET POT2). Method of reproducing failure code: Starting switch ON and operate bucket lever Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S02 (male) Between (1) and (4) Between (1), (2), (3), (4) and ground Resistance 3.2 0.64 kz Min. 1 Mz

No.

1. Prepare with starting switch at OFF position. 2. Disconnect connector S02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. S02 Defective bucket EPC lever poten1 tiometer tor (internal open or short circuit) Between (4) and (1) Bucket EPC lever Ladder at any position Set lever to NEUTRAL. Between (3) and (1) Move to TILT (before detent) Move to TILT (detent position) Full DUMP operation Set lever to NEUTRAL. Between (2) and (1) Move to TILT (before detent) Move to TILT (detent position) Full DUMP operation Voltage 4.85 to 5.15 V 2.402.60 V 3.644.14 V 3.864.36 V 0.641.14 V 2.402.60 V 0.861.36 V 0.641.14 V 3.864.36 V

WA1200-6

40-359

Troubleshooting by failure code Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure

No.

Cause

Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (10) and S02 Max. 1 z (female) (2) Open circuit in wiring harness 2 Wiring harness between L05 (female) (7) and S02 (open circuit or defective contact) Max. 1 z (female) (3) Resistance Wiring harness between L05 (female) (10) and S02 Max. 1 z (female) (1) Wiring harness between L05 (female) (22) and S02 Max. 1 z (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 Min. 1 Mz Ground fault in wiring harness (female) (1) to S02 (female) (2) 3 Between ground and wiring harness from L05 Min. 1 Mz (contact with ground circuit) (female) (7) to S02 (female) (3) Resistance Between ground and wiring harness from L05 Min. 1 Mz (female) (22) to S02 (female) (4), and to circuit branch end 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L05 Max. 1 V Hot short circuit in wiring harness (female) (1) to S02 (female) (2) 4 Between ground and wiring harness from L05 (contact with 24 V circuit) Max. 1 V (female) (7) to S02 (female) (3) Voltage Between ground and wiring harness from L05 (female) (22) to S02 (female) (4), and to circuit Max. 1 V branch end 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 Between (22) and (10) Bucket EPC lever Ladder at any position Set lever to NEUTRAL. Defective boom bucket & AJSS 5 controller Between (7) and (10) Move to TILT (before detent) Move to TILT (detent position) Full DUMP operation Set lever to NEUTRAL. Between (1) and (10) Move to TILT (before detent) Move to TILT (detent position) Full DUMP operation Voltage 4.85 to 5.15 V 2.402.60 V 3.644.14 V 3.864.36 V 0.641.14 V 2.402.60 V 0.861.36 V 0.611.14 V 3.964.36 V

40-360

WA1200-6

Troubleshooting by failure code Failure code [DK5BL8] Bucket lever potentiometer (main & sub) failure

Related circuit diagram

40-361

WA1200-6

40-361

Troubleshooting by failure code Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)

Failure code [DK5CKA] Bucket lever potentiometer (sub) (Disconnect/Short Circuit)

Action level E03 Failure code DK5CKA Failure Bucket lever potentiometer system error (input signal out of range) (Bucket lever & AJSS controller system)

40-362

Detail of failure Open circuit or ground fault has occurred in the bucket lever potentiometer circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S02 (male) Between (2) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective bucket lever potentiometer

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (10) and S02 Max. 1 z (female) (2) Resistance Wiring harness between L05 (female) (22) and S02 Max. 1 z (female) (4) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L05 Min. 1 Mz (female) (1) to S02 (female) (2) Resistance Between ground and wiring harness from L05 Min. 1 Mz (female) (22) to S02 (female) (4) a Be ready with starting switch OFF, then turn starting switch to ON position and perform troubleshooting. L05 (female) Between (22) and ground Voltage 4.95.1 V

Related circuit diagram

40-362

40-362

WA1200-6

Troubleshooting by failure code Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short

Failure code [DK5CKY] Bucket lever potentiometer (sub) hot short

Action level E03 Failure code DK5CKY Failure Bucket lever potentiometer system error (input signal out of range) (Bucket lever & AJSS controller system)

40-363

Detail of failure Open circuit or ground fault occurs in bucket lever potentiometer circuit. Action of controller Problem on machine Related information No. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed, connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S02 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S02 (male) Between (2) and ground Between (4) and ground Resistance Min. 1 Mz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective bucket lever potentiometer

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, S02 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn the starting switch to OFF position, then perform troubleshooting. (contact with +5 V circuit) Between ground and wiring harness between L05 Resistance Min. 1 Mz (female) (1) and S02 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L05 (female) Voltage Between (22) and ground 4.9 to 5.1 V

Related circuit diagram

40-363

WA1200-6

40-363

Troubleshooting by failure code Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit)

Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit) 40-364

Action level E01 Failure code DKA0KA Failure Boom angle sensor system error (input signal out of range) (Boom bucket & AJSS controller system)

Detail of failure Open circuit or ground fault has occurred in boom angle sensor circuit Action of controller Problem on machine
q q

Steering source pressure control EPC solenoid output: OFF Control the frame angle sensor signal voltage as the input voltage.

Effective steering speed is different to the right and left.

a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective frame angle sensor F04 (male) Between (A) and (B) Between (B) and (C) Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Change boom angle Resistance 0.25 kz 05 kz

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (8) and F04 Resistance Max. 1 z (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 Resistance Min. 1 Mz (female) (8) to F04 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) Between (8) and ground Voltage 4.95.1 V

40-364

WA1200-6

Troubleshooting by failure code Failure code [DKA0KA] Boom angle sensor (Disconnect/Short Circuit)

Related circuit diagram

40-365

WA1200-6

40-365

Troubleshooting by failure code Failure code [DKA0KX] Boom angle sensor circuit failure

Failure code [DKA0KX] Boom angle sensor circuit failure

Action level E01 Failure code DKA0KX Failure Boom angle sensor system error (input signal out of range) (Monitor panel controller system)

40-36

Detail of failure Open circuit, short circuit, or ground fault has occurred in boom angle sensor (potentiometer) circuit Action of conRemote positioner function: OFF troller Problem on machine Related information No. Remote positioner function does not operate a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. F04 (male) Between (A) and (B) Between (B) and (C) Resistance 0.25 kz 05 kz

Boom angle potentiometer (potentiometer) defective

1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness Wiring harness between FC05 (female) (6) and F04 Max. 1 z (wire breakage or defective con- (female) (B) Wiring harness between FC01 (female) (16) and tact of connector) Resistance Max. 1 z F04 (female) (C) Wiring harness between FC01 (female) (10) and Max. 1 z F04 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from FC05 (contact with ground circuit) (female) (6) to F04 (female) (B), from FC01 Resistance Min. 1 Mz (female) (10) to F04 (female) (C), from FC01 (female) (10) to F04 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC05, F04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from FC05 (contact with 5 V circuit) Max. 1 V (female) (6) to F04 (female) (B) Voltage Between ground and wiring harness from FC05 Max. 1 V (female) (10) to F04 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective monitor panel controller FC01 (female) Voltage (8)(16) 0.34.8 V

40-366

WA1200-6

Troubleshooting by failure code Failure code [DKA0KX] Boom angle sensor circuit failure

Related circuit diagram

40-367

WA1200-6

40-367

Troubleshooting by failure code Failure code [DKA0KY] Boom angle sensor circuit hot short

Failure code [DKA0KY] Boom angle sensor circuit hot short

Action level E01 Failure code DKA0KY Failure Boom angle sensor system error (input signal out of range) (Boom bucket & AJSS controller system)

40-368

Detail of failure Open circuit or ground fault has occurred in the bucket lever potentiometer circuit Action of controller Problem on machine
q q

Steering source pressure control EPC solenoid output: OFF Control the frame angle sensor signal voltage as the input voltage.

Effective steering speed is different to the right and left.

a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective frame angle sensor F04 (male) Between (A) and (B) Between (B) and (C) Change frame angle Resistance 0.25 kz 05 kz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, F04 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn the starting switch to OFF position, then perform troubleshooting. (contact with +5 V circuit) Between ground and wiring harness from L05 Resistance Min. 1 Mz (female) (8) to F04 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L05 (female) Voltage Between (8) and ground 4.95.1 V

40-368

WA1200-6

Troubleshooting by failure code Failure code [DKA0KY] Boom angle sensor circuit hot short

Related circuit diagram

40-369

WA1200-6

40-369

Troubleshooting by failure code Failure code [DKA0L0] Boom angle sensor failure

Failure code [DKA0L0] Boom angle sensor failure

Action level E01 Failure code DKA0L0 Failure Frame angle sensor system error (input signal out of range) (Boom bucket & AJSS controller system)

40-370

Detail of failure Improper positioning has occurred in boom angle sensor circuit Action of controller Problem on machine Related information No.
q

Boom angle is not recognized correctly

Remote positioner function does not work, or semi auto digging malfunctions a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.

1 Defective frame angle sensor

F04 (male) Between (A) and (B) Between (B) and (C) Change boom angle

Resistance 0.25 kz 05 kz

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

Defective installation of boom 4 angle sensor (Center misaligned)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (8) and F04 Resistance Max. 1 z (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, F04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 Resistance Min. 1 Mz (female) (8) to F04 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, FC01 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. FC01, L05 (female) L05(8)FC01(10) Change boom angle Voltage 0.5 4.5 V

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) Between (8) and ground Voltage 4.95.1 V

40-370

WA1200-6

Troubleshooting by failure code Failure code [DKA0L0] Boom angle sensor failure

Related circuit diagram

40-371

WA1200-6

40-371

Troubleshooting by failure code Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit)

Failure code [DKD0KA] Frame angle sensor (Disconnect/Short Circuit) 40-372

Action level E01 Failure code DKD0KA Failure Frame potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

Detail of failure Open circuit or ground fault has occurred in the circuit Action of controller Problem on machine
q q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Engine cannot be started Fine control of steering cannot be made a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector R32 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective frame potentiometer R32 (male) Between (A) and (B) Between (B) and (C) Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Change frame angle Resistance 0.25 kz 05 kz

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, R32 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L05 (female) (3) and R32 Resistance Max. 1 z (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, R32 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L05 Resistance Min. 1 Mz (female) (3) to R32 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) (10)(22) Voltage 4.95.1 V

Related circuit diagram

40-372

40-372

WA1200-6

Troubleshooting by failure code Failure code [DKD0KY] Frame angle sensor circuit hot short

Failure code [DKD0KY] Frame angle sensor circuit hot short

Action level E01 Failure code DKD0KY Failure Frame potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

40-373

Detail of failure Hot short circuit has occurred Action of controller Problem on machine
q q q

Detail of failure is displayed in yellow on the multi-monitor screen.

Engine cannot be started Fine control of steering cannot be made a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector R32 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective frame potentiometer R32 (male) Between (A) and (B) Between (B) and (C) Change frame angle Resistance 0.25 kz 05 kz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L05, R32 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness from L05 Voltage Max. 1 V (female) (3) to R32 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L05 (female) Voltage (10)(22) 4.95.1 V

Related circuit diagram

40-373

WA1200-6

40-373

Troubleshooting by failure code Failure code [DKD0KZ] Frame and steering angle sensor failure

Failure code [DKD0KZ] Frame and steering angle sensor failure

Action level E01 Failure code DKD0KZ Failure Frame potentiometer system error (input signal out of range) (Boom bucket & AJSS controller system)

40-374

Detail of failure Open circuit or ground fault has occurred in frame angle sensor circuit Action of controller Problem on machine
q q

Steering source pressure control EPC solenoid output: OFF Control the frame angle sensor signal voltage as the input voltage.

Effective steering speed is different to the right and left.

a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector R32, R32 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective frame potentiometer S30, R32 (male) Between (A) and (B) Between (B) and (C) Change frame angle Resistance 0.25 kz 05 kz

Defective installation of frame 2 angle sensor (Center misaligned)

1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) Change frame angle Voltage (3)(10) 0.5 4.5 V (3)(9) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L05 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L05 (female) (10)(22) Voltage 4.95.1 V

Defective boom bucket & AJSS controller

Related circuit diagram

40-374

40-374

WA1200-6

Troubleshooting by failure code Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect

Failure code [DKH0KA] Angle sensor circuit (FR) Disconnect

Action level E01 Failure code DKH0KA Failure Pitch angle sensor system error (input signal out of range) (Transmission controller system)

40-375

Detail of failure Open circuit or ground fault has occurred in the pitch angle sensor circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector L141 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Replace with a normally operating sensor Failure code disappears 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L141 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L02 (female) (7) and L141 Max. 1 z (female) (B) Wiring harness between L02 (female) (4) and L141 Resistance Max. 1 z (female) (A) Wiring harness between L02 (female) (16) and Max. 1 z L141 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L141 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L02 Min. 1 Mz (female) (7) to L141 (female) (B) Resistance Between ground and wiring harness from L02 Min. 1 Mz (female) (4) to L141 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 (female) Between (7) and ground Voltage 4.95.1 V
q q

Controls machine based on information obtained before occurrence of failure Detail of failure is displayed in yellow on the multi-monitor screen.

1 Defective pitch angle sensor

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

4 Defective transmission controller

Related circuit diagram

40-375

WA1200-6

40-375

Troubleshooting by failure code Failure code [DKH0KB] Angle sensor circuit (FR) Hot short

Failure code [DKH0KB] Angle sensor circuit (FR) Hot short

Action level E01 Failure code DKH0KB Failure Angle sensor system error (input signal out of range) (Transmission controller system)

40-376

Detail of failure Hot short circuit occurs in angle sensor circuit. Action of controller Problem on machine Related information No. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed, connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector L141 and replace current sensor with normally operating sensor. 3. Turn starting switch to ON position and perform troubleshooting. Replace current sensor with normally operating Failure code disappears sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L141 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L02 Resistance Min. 1 Mz (female) (7) and L141 (female) (B) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 (female) Between (7) and ground Voltage 4.9 to 5.1 V
q

Controls machine based on information obtained before occurrence of failure,

1 Defective angle sensor

Ground fault in wiring harness (contact with +24 V circuit)

3 Defective transmission controller

Related circuit diagram

40-376

40-376

WA1200-6

Troubleshooting by failure code Failure code [DKH0KB] Angle sensor circuit (FR) Hot short

WA1200-6

40-377

Troubleshooting by failure code Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect

Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect

Action level E01 Failure code DKH1KA Failure Pitch angle sensor system error (input signal out of range) (Transmission controller system)

40-378

Detail of failure Open circuit or ground fault has occurred in the pitch angle sensor circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect sensor L142 and replace with a normally operating sensor. 3. Turn starting switch to ON position and perform troubleshooting. Replace with a normally operating sensor Failure code disappears 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L142 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L28 (female) (1) and L142 Max. 1 z (female) (1) Wiring harness between L02 (female) (1) and L142 Max. 1 z (female) (B) Resistance Wiring harness between L02 (female) (4) and L142 Max. 1 z (female) (A) Wiring harness between L02 (female) (16) and Max. 1 z L142 (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L142 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L28 Min. 1 Mz (female) (1) to L142 (female) (B) Between ground and wiring harness from L02 Resistance Min. 1 Mz (female) (1) to L142 (female) (B) Between ground and wiring harness from L02 Min. 1 Mz (female) (4) to L142 (female) (A) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L02 (female) (1)(4) Voltage 4.95.1 V
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1 Defective frame angle sensor

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

4 Defective transmission controller

40-378

WA1200-6

Troubleshooting by failure code Failure code [DKH1KA] Angle sensor circuit (LR) Disconnect

Related circuit diagram

40-379

WA1200-6

40-379

Troubleshooting by failure code Failure code [DKH1KB] Angle sensor circuit (LR) Hot short

Failure code [DKH1KB] Angle sensor circuit (LR) Hot short

Action level E01 Failure code DKH1KB Failure Angle sensor system error (input signal out of range) (Transmission controller system)

40-380

Detail of failure Hot short circuit occurs in angle sensor circuit. Action of controller Problem on machine Related information No. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed, connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect sensor L142 and replace current sensor with normally operating sensor. 1 Defective frame angle sensor 3. Turn starting switch to ON position and perform troubleshooting. Replace current sensor with normally operating Failure code disappears sensor 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L02, L142 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to OFF position, then perform troubleshooting. (contact with +24 V circuit) Between ground and wiring harness between L02 Resistance Min. 1 Mz (female) (1) and L142 (female) (B) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L02 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller L02 (female) Voltage (1) to (4) 4.9 to 5.1 V

Related circuit diagram

40-380

40-380

WA1200-6

Troubleshooting by failure code Failure code [DKH1KB] Angle sensor circuit (LR) Hot short

WA1200-6

40-381

Troubleshooting by failure code Failure code [DLE2KA] Engine Speed Sensor Disconnection

Failure code [DLE2KA] Engine Speed Sensor Disconnection

Action level E03 Failure code DLE2KA Failure Engine speed sensor system error (Transmission controller system)

40-382

Detail of failure Open circuit or hot short circuit has occurred in engine speed sensor circuit Action of controller
q q

Travels with engine speed at 2,100 rpm 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T17 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T17 (male) Between (1) and (2) Resistance 100500 z

1 Defective engine speed sensor

1. Prepare with starting switch at OFF position. 2. Disconnect connector L03, T17 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between L03 (female) (10) and T17 Max. 1 z (female) (1) tact of connector) Resistance Wiring harness between L03 (female) (29) and T17 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness 3 Between ground and wiring harness from L03 Max. 1 V (contact with power supply circuit) (female) (10) to T17 (female) (1) Voltage Between ground and wiring harness from L03 Max. 1 V (female) (29) to T17 (female) (2) a Be ready with starting switch in OFF position, and perform troubleshooting without turning stating switch to ON position. 4 Defective transmission controller L03(female) Resistance Between (10) and (29) Min. 1 Mz

40-382

WA1200-6

Troubleshooting by failure code Failure code [DLE2KA] Engine Speed Sensor Disconnection

Related circuit diagram

40-383

WA1200-6

40-383

Troubleshooting by failure code Failure code [DLE2LC] Engine Speed Sensor Short Circuit

Failure code [DLE2LC] Engine Speed Sensor Short Circuit

Action level E03 Failure code DLE2LC Failure Engine speed sensor system error (Transmission controller system)

40-384

Detail of failure Ground fault has occurred in engine speed sensor circuit Action of conJudges as engine is stopped troller Problem on ECMV does not operate 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T17 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T17 (male) Between (1) and (2) Ground fault in wiring harness (Contact with ground circuit) Resistance 100500 z

1 Defective engine speed sensor

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connector L03, T17 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Resistance Min. 1 Mz (female) (10) to T17 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L03(female) Between (10) and (29) Resistance Min. 1 Mz

40-384

WA1200-6

Troubleshooting by failure code Failure code [DLE2LC] Engine Speed Sensor Short Circuit

Related circuit diagram

40-385

WA1200-6

40-385

Troubleshooting by failure code Failure code [DLF6LC] Tire speed sensor circuit

Failure code [DLF6LC] Tire speed sensor circuit

WA1200-6

40-386

Action level E03

Failure code DLF6LC

Failure

Tire speed sensor system error (Transmission controller system)

Detail of failure Open circuit or hot short circuit has occurred in tire speed sensor circuit Action of conJudges as tire speed is zero troller Problem on Judges as tire is slipping 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector F15 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. F15 (male) Between (1) and (2) Resistance 100500 z

1 Defective tire speed sensor

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, F15 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (wire breakage or defective con- Wiring harness between L03 (female) (37) and F15 Max. 1 z tact of connector) (female) (B) Resistance Wiring harness between L03 (female) (39) and F15 Max. 1 z (female) (C) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, F15 and connect T-adapter. Ground fault in wiring harness 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) (37) to F15 (female) (B) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, F15, V1 in turn, and connect T-adapter. Hot short circuit in wiring harness 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness from L03 Voltage Max. 1 V (female) (37) to F15 (female) (B) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Defective transmission controller L03(female) Resistance Between (37) and (39) Min. 1 Mz

40-386

WA1200-6

Troubleshooting by failure code Failure code [DLF6LC] Tire speed sensor circuit

Related circuit diagram

40-387

WA1200-6

40-387

Troubleshooting by failure code Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect

Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect

Action level E03 Failure code DLFALC Failure Modulation clutch speed sensor system error (Transmission controller system)

40-38

Detail of failure Open circuit or hot short circuit has occurred in modulation clutch speed sensor system Action of conAssumes that modulation clutch outlet speed is 2100 rpm troller Problem on machine Related information No. Automatic shift does not operate a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T16 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T15 (male) Between (1) and (2) Between (1), (2) and ground Resistance 5001000 kz Min. 1 Mz

Defective modulation clutch outlet speed sensor

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, T16 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between L03 (female) (30) and T16 Max. 1 z (female) (1) tact of connector) Resistance Wiring harness between L03 (female) (29) and T16 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, T16 and connect T-adapter. Hot short circuit in wiring harness 3 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness from L03 Voltage Max. 1 V (female) (30) to T16 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 4 Defective transmission controller L03(female) Voltage Between (30) and ground during illuminance decrease adjustment

40-388

WA1200-6

Troubleshooting by failure code Failure code [DLFAKA] Mod/c Output Speed Sensor Disconnect

Related electrical circuit diagram

40-389

WA1200-6

40-389

Troubleshooting by failure code Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit

Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit

Action level E03 Failure code DLFALC Failure Modulation clutch speed sensor system error (Transmission controller system)

40-390

Detail of failure Ground fault has occurred in modulation clutch speed sensor system Action of conAssumes that modulation clutch outlet speed is 2100 rpm troller Problem on machine Related information No. Automatic shift does not operate a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T16 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T15 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 5001000 kz Min. 1 Mz

Defective modulation clutch outlet speed sensor

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, T16 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L03 Resistance Min. 1 Mz (female) (30) to T16 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L03(female) Between (30) and ground Voltage Max. 1 V

40-390

WA1200-6

Troubleshooting by failure code Failure code [DLFALC] Mod/c Output Speed Sensor Short Circuit

Related electrical circuit diagram

40-391

WA1200-6

40-391

Troubleshooting by failure code Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit

Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit
Action level E03
q q

40-392

Failure code DLT4KB

Failure

Travel speed sensor system error (Transmission controller system)

Detail of failure Ground fault has occurred in the travel speed sensor circuit Action of controller Tire slip prevention control is cancelled Modulation clutch control is cancelled (clutch is engaged directly) 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 a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T15 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective travel speed sensor T15 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 5001000 kz Min. 1 Mz

No.

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, T15 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Between ground and wiring harness from L03 Resistance Min. 1 Mz (female) (20) to T15 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L03(female) Between (20) and ground Voltage Max. 1 V

40-392

WA1200-6

Troubleshooting by failure code Failure code [DLT4KB] Output Shaft Speed Sensor (1) Short Circuit

Related electrical circuit diagram

40-393

WA1200-6

40-393

Troubleshooting by failure code Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection

Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection

Action level E03 Failure code DLT4KX Failure Travel speed sensor system error (Transmission controller system)

40-394

Detail of failure Open circuit or hot short circuit has occurred in transmission output shaft speed circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T15 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T15 (male) Between (1) and (2) Resistance 5001000 kz
q

Turns the centralized warning lamp and alarm buzzer ON.

1 Defective travel speed sensor

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, T15 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective con- Wiring harness between L03 (female) (30) and T15 Max. 1 z tact of connector) (female) (1) Resistance Wiring harness between L03 (female) (29) and T15 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L03, T15 and connect T-adapter. Hot short circuit in wiring harness 3 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Wiring harness between L03 (female) (30) and T15 Voltage Max. 1 V (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L03 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 4 Defective transmission controller L03(female) Voltage Between (20) and ground Max. 1 V

40-394

WA1200-6

Troubleshooting by failure code Failure code [DLT4KX] Output Shaft Speed Sensor (1) Disconnection

Related circuit diagram

40-395

WA1200-6

40-395

Troubleshooting by failure code Failure code [DT20KB] Transmission cut off indicator Output short circuit

Failure code [DT20KB] Transmission cut off indicator Output short circuit
Action level E01 Failure code DT20KB Failure Transmission cutoff switch system error (input signal out of range) (Transmission controller system)

40-396

Detail of failure Open circuit or ground fault occurs in built-in indicator of transmission cutoff switch. Action of controller Problem on machine Related information No.
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Cutoff indicator does not light up. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch S23 and replace it with normally operating switch. 3. Turn starting switch to ON position and perform troubleshooting. Replace current switch with normally Failure code disappears operating switch 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, S23 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (8) and S23 Resistance Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, S23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L04 Resistance Min. 1 Mz (female) (8) and S23 (female) (2)

Defective transmission cutoff switch

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Ground fault in wiring harness (contact with ground circuit)

Related circuit diagram

40-396

40-396

WA1200-6

Troubleshooting by failure code Failure code [DT21KB] Speed Control indicator Output short circuit

Failure code [DT21KB] Speed Control indicator Output short circuit

Action level E01 Failure code DT21KB Failure Travel speed control indicator system error (input signal out of range) (Transmission controller system)

40-397

Detail of failure An error occurs in travel speed control indicator circuit. Action of controller Problem on machine Related information No. Travel speed control indicator does not light up. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect switch FC22 and replace it with normally operating switch. Defective travel speed control indi1 3. Turn starting switch to ON position and perform troubleshooting. cator Replace current switch with normally Failure code disappears operating switch 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, FC22 and connect T-adapter. Ground fault in wiring harness 2 3. Turn starting switch to OFF position, then perform troubleshooting. (contact with ground circuit) Between ground and wiring harness between L04 Resistance Min. 1 Mz (female) (18) and FC22 (female) (6)

Related circuit diagram

40-397

WA1200-6

40-397

Troubleshooting by failure code Failure code [DUM8KB] VHMS Operation lamp Short Circuit

Failure code [DUM8KB] VHMS Operation lamp Short Circuit

Action level E01 Failure code DUM8KB Failure Boom kick-out solenoid system error (KOMTRAX Plus controller system)

40-398

Detail of failure Ground fault or hot short circuit occurs in circuit. Action of controller Problem on machine Related information No. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect switches RA10, RA11 and replace them with normally operating switches. 1 Defective lift arm kick-out relay 3. Turn starting switch to ON position and perform troubleshooting. Replace current switches with norFailure code disappears mally operating switches 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1, RA10, RA11 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness 2 Between ground and wiring harness between V1 (contact with ground circuit) Min. 1 Mz (female) (14) and RA10 (female) (2) Resistance Between ground and wiring harness between V1 Min. 1 Mz (female) (14) and RA11 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors V1, RA10, RA11 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness 3 Between ground and wiring harness between V1 (contact with +24 V circuit) Max. 1 V (female) (14) and RA10 (female) (2) Voltage Between ground and wiring harness between V1 Max. 1 V (female) (14) and RA11 (female) (2)

40-398

WA1200-6

Troubleshooting by failure code Failure code [DUM8KB] VHMS Operation lamp Short Circuit

Related circuit diagram

40-39

WA1200-6

40-399

Troubleshooting by failure code Failure code [DV00KY] Buzzer circuit hotshort (for usually)

Failure code [DV00KY] Buzzer circuit hotshort (for usually)

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q

40-40

Failure code DV00KY

Failure

Alarm buzzer: short circuit (Machine monitor system)

Hot short is detected in the alarm buzzer output circuit. Stops alarm buzzer output. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Alarm buzzer does not sound The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code: 40925, D-OUT-0). Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector L42 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L42 (female) Starting switch ON Voltage 20 to 30 V

q q q

For 2 secs after ON 20 to 30 V (Alarm buzzer sounds.) For 2 to 3 secs after ON Between (1) and (2) (Alarm buzzer does not Max. 1 V sound.) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC01, L42 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from FC01 Voltage Max. 1 V (female) (14) to L42 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC01 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. FC01 3 Defective machine monitor Starting switch ON For 2 secs after ON Between (14) and ground (Alarm buzzer sounds.) For 2 to 3 secs after ON (Alarm buzzer does not sound.) Voltage 20 to 30 V Max. 1 V 20 to 30 V

Defective alarm buzzer (Internal short circuit)

Between (1) and ground

40-400

WA1200-6

Troubleshooting by failure code Failure code [DV00KY] Buzzer circuit hotshort (for usually)

Related electrical circuit diagram

40-401

WA1200-6

40-401

Troubleshooting by failure code Failure code [DV01KY] Buzzer circuit hotshort (for special)

Failure code [DV01KY] Buzzer circuit hotshort (for special)

Action level E01 Detail of failure Action of controller Problem on machine Related information No.
q q q

40-402

Failure code DV01KY

Failure

Alarm buzzer: short circuit (Machine monitor system)

Hot short is detected in the alarm buzzer output circuit. Stops alarm buzzer output. Even if cause of failure disappears, machine does not become normal until starting switch is turned to OFF position. Alarm buzzer does not sound The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code: 40925, D-OUT-0). Method of reproducing failure code: Turn starting switch to ON position. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector L43 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L43 (female) Starting switch ON Voltage 20 to 30 V

q q q

For 2 secs after ON 20 to 30 V (Alarm buzzer sounds.) For 2 to 3 secs after ON Between (1) and (2) (Alarm buzzer does not Max. 1 V sound.) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors FC01, L43 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from FC01 Voltage Max. 1 V (female) (13) to L43 (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector FC01 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. FC01 3 Defective machine monitor Starting switch ON For 2 secs after ON Between (14) and ground (Alarm buzzer sounds.) For 2 to 3 secs after ON (Alarm buzzer does not sound.) Voltage 20 to 30 V Max. 1 V 20 to 30 V

Defective alarm buzzer (Internal short circuit)

Between (1) and ground

40-402

WA1200-6

Troubleshooting by failure code Failure code [DV01KY] Buzzer circuit hotshort (for special)

Related electrical circuit diagram

40-403

WA1200-6

40-403

Troubleshooting by failure code Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection

Failure code [DW23KA] T/M E-POCV (F bypass) Solenoid Disconnection40-404

Action level E03 Failure code DW23KA Failure F bypass valve system error (open circuit) (Transmission controller system)

Detail of failure Open circuit occurs in F bypass valve circuit Action of conInterrupts solenoid output troller Problem on machine Related information No. Shifting shocks are noticed at F clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T22 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective F bypass solenoid T22 (male) Between (1) and (2) Between (1), (2) and ground Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Resistance 5 to 15 z Min. 1 Mz

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T22 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (7) and T22 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. L04 (male) Between (7) and ground Resistance Min. 1 Mz

Related circuit diagram

40-404

40-404

WA1200-6

Troubleshooting by failure code 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 level E03 Failure code DW23KB Failure F bypass valve system error (ground fault) (Transmission controller system)

Detail of failure Ground fault occurs in F bypass valve circuit. Action of conInterrupts solenoid output troller Problem on machine Related information No. Shifting shocks are noticed at F clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T22 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective F bypass solenoid T22 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 5 to 15 z Min. 1 Mz

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T22 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L04 Resistance Min. 1 Mz (female) (7) and T22 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. L04 (male) Between (7) and ground Resistance Min. 1 Mz

Related circuit diagram

40-405

WA1200-6

40-405

Troubleshooting by failure code 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
Action level E03 Failure code DW23KY Failure F bypass valve system error (hot short circuit) (Transmission controller system)

40-406

Detail of failure Hot short circuit occurs in F bypass valve circuit. Action of conInterrupts solenoid output. troller Problem on machine Related information No. Shifting shocks are noticed at F clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performing while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T22 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective F bypass solenoid T22 (male) Between (1) and (2) Between (1), (2) and ground Resistance 5 to 15 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T22 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L04 Voltage Min. 1 V (female) (7) and T22 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 3 Defective transmission controller L04 (male) Resistance Between (7) and ground Min. 1 Mz

Related circuit diagram

40-406

40-406

WA1200-6

Troubleshooting by failure code Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection

Failure code [DW24KA] T/M E-POCV (R bypass) Solenoid Disconnection40-407

Action level E03 Failure code DW24KA Failure R bypass valve system error (open circuit) (Transmission controller system)

Detail of failure Open circuit occurs in R bypass valve circuit. Action of conInterrupts solenoid output. troller Problem on machine Related information No. Shifting shocks are noticed at R clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T21 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective R bypass solenoid T21 (male) Between (1) and (2) Between (1), (2) and ground Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Resistance 5 to 15 z Min. 1 Mz

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T21 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (17) and T21 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. L04 (male) Between (17) and ground Resistance Min. 1 Mz

Related circuit diagram

40-407

WA1200-6

40-407

Troubleshooting by failure code 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 level E03 Failure code DW24KB Failure R bypass valve system error (ground fault) (Transmission controller system)

Detail of failure Ground fault occurs in R bypass valve circuit. Action of conInterrupts solenoid output. troller Problem on machine Related information No. Shifting shocks are noticed at R clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is made while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T21 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective R bypass solenoid T21 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 5 to 15 z Min. 1 Mz

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T21 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L04 Resistance Min. 1 Mz (female) (17) and T21 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. L04 (male) Between (17) and ground Resistance Min. 1 Mz

Related circuit diagram

40-408

40-408

WA1200-6

Troubleshooting by failure code 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
Troubleshooting by failure code 40-409 WA1200-6

40-409

Action level E03

Failure code DW24KY

Failure

R bypass valve system error (hot short circuit) (Transmission controller system)

Detail of failure Hot short circuit occurs in R bypass valve circuit Action of conInterrupts solenoid output troller Problem on machine Related information No. Shifting shocks are noticed at R clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T21 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective R bypass solenoid T21 (male) Between (1) and (2) Between (1), (2) and ground Resistance 5 to 15 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T21 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L04 Voltage Max. 1 V (female) (17) and T21 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 3 Defective transmission controller L04 (male) Resistance Between (17) and ground Min. 1 Mz

Related circuit diagram

40-409

WA1200-6

40-409

Troubleshooting by failure code Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection

Failure code [DW25KA] T/M E-POCV (1st bypass) Solenoid Disconnection 40-410
Action level E03 Failure code DW25KA Failure 1st bypass valve system error (open circuit) (Transmission controller system)

Detail of failure Open circuit occurs in 1st bypass valve circuit. Action of conInterrupts solenoid output. troller Problem on machine Related information No. Shifting shocks are noticed at 1st clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is ferformed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T20 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective 1st bypass solenoid T20 (male) Between (1) and (2) Between (1), (2) and ground Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Resistance 5 to 15 z Min. 1 Mz

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T20 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (27) and T20 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. L04 (male) Between (27) and ground Resistance Min. 1 Mz

Related circuit diagram

40-410

40-410

WA1200-6

Troubleshooting by failure code 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 level E03 Failure code DW25KB Failure 1st bypass valve system error (ground fault) (Transmission controller system)

Detail of failure Ground fault occurs in 1st bypass valve circuit. Action of conInterrupts solenoid output. troller Problem on machine Related information No. Shifting shocks are noticed at 1st clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T20 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 1 Defective 1st bypass solenoid T20 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 5 to15 z Min. 1 Mz

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T20 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L04 Resistance Min. 1 Mz (female) (27) and T20 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. L04 (male) Between (27) and ground Resistance Min. 1 Mz

Related circuit diagram

40-41

WA1200-6

40-411

Troubleshooting by failure code 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 level E03 Failure code DW25KY Failure 1st bypass valve system error (hot short circuit) (Transmission controller system)

Detail of failure Hot short circuit occurs in 1st bypass valve circuit. Action of conInterrupts solenoid output. troller Problem on machine Related information No. Shifting shocks are noticed at 1st clutch and time to engage becomes longer (eventually engages). a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect switch T20 and connect T-adapter. 3. Turn starting switch to OFF positon, then perform troubleshooting. 1 Defective 1st bypass solenoid T20 (male) Between (1) and (2) Between (1), (2) and ground Resistance 5 to 15 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T20 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L04 Voltage Max. 1 V (female) (27) and T20 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. 3 Defective transmission controller L04 (male) Resistance Between (27) and ground Min. 1 Mz

Related circuit diagram

40-412

40-412

WA1200-6

Troubleshooting by failure code Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection

Failure code [DW4PKA] Boom EPC solenoid (raise1) disconnection

Action level E03 Failure code DW4PKA Failure Boom RAISE EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-413

Detail of failure Open circuit has occurred in boom RAISE EPC solenoid (1) circuit Action of controller Problem on machine Related information No.
q

Boom LOWER EPC solenoid (1) cannot be energized

Boom LOWER speed is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR23 (male) Between (1), (3) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective boom RAISE EPC solenoid (1)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (28) and Resistance Max. 1 z HR23 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (28)(13) Voltage 4.95.1 V

Related circuit diagram

40-413

WA1200-6

40-413

Troubleshooting by failure code Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault

Failure code [DW4PKB] Boom Raise EPC solenoid (1) ground fault
Action level E03 Failure code DW4PKB Failure Boom Raise EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-414

Detail of failure Ground fault occurs in boom Raise EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom Raise speed is slow. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR23 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR23 (male) Between (1), (3) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective boom Raise EPC solenoid (1)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR23 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L07 Resistance Min. 1 Mz (female) (28) and HR23 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (28) to (13) Voltage 4.9 to 5.1 V

Related circuit diagram

40-414

40-414

WA1200-6

Troubleshooting by failure code Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short

Failure code [DW4PKY] Boom Raise EPC solenoid (1) hot short
Action level E03 Failure code DW4PKY Failure Boom Raise EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-415

Detail of failure Hot short circuit occurs in boom Raise EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom Raise speed is slow. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR23 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR23 (male) Between (1), (3) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective boom Raise EPC solenoid (1)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR23 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L07 Voltage Max. 1 V (female) (28) and HR23 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Voltage (28) to (13) 4.9 to 5.1 V

Related circuit diagram

40-415

WA1200-6

40-415

Troubleshooting by failure code Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection

Failure code [DW4QKA] Boom Lower EPC solenoid (1) disconnection 40-416
Action level E03 Failure code DW4QKA Failure Boom Lower EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

Detail of failure Open circuit occurs in boom Lower EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Boom Lower EPC solenoid (1) cannot be energized.

Boom Lower speed is slow. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR24 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting.

1 Defective EPC solenoid (1)

HR24 (male) Between (1), (3) and ground Between (1) and (2)

Resistance Min. 1 Mz 5 to 15 kz

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR24 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (38) and Resistance Max. 1 z HR24 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (38) to (13) Voltage 4.9 to 5.1 V

Related circuit diagram

40-416

40-416

WA1200-6

Troubleshooting by failure code Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit

Failure code [DW4QKB] Boom EPC solenoid (take down1) short circuit 40-417
Action level E03 Failure code DW4QKB Failure Boom LOWER EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

Detail of failure Ground fault has occurred in boom LOWER EPC solenoid (1) circuit Action of controller Problem on machine
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom LOWER speed is slow

a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR24 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective frame angle sensor HR24 (male) Between (1), (3) and ground Between (1) and (2) Ground fault in wiring harness (contact with ground circuit) Resistance Min. 1 Mz 515 kz

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR24 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Resistance Min. 1 Mz (female) (38) to HR24 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L07 (female) (38)(13) Voltage 4.95.1 V

Related circuit diagram

40-417

WA1200-6

40-417

Troubleshooting by failure code Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short

Failure code [DW4QKY] Boom EPC solenoid (take down1) hot short
Action level E03 Failure code DW4QKY Failure Boom LOWER EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-418

Detail of failure Hot short circuit has occurred in boom LOWER EPC solenoid (1) circuit Action of controller Problem on machine
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom LOWER speed is slow

a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the Related informonitor 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 No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR24 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective frame angle sensor HR24 (male) Between (1), (3) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR24 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness from L07 Voltage Max. 1 V (female) (38) to HR24 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Voltage (38)(13) 4.95.1 V

Related circuit diagram

40-418

40-418

WA1200-6

Troubleshooting by failure code Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection

Failure code [DW4RKA] Bucket tilt EPC solenoid (1) disconnection

Action level E03 Failure code DW4RKA Failure Bucket tilt EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-419

Detail of failure Open circuit occurs in bucket tilt EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Bucket tilt EPC solenoid (1) cannot be energized.

Bucket tilt speed is slow. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR25 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR25 (male) Between (1), (3) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective bucket Tilt EPC solenoid (1)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR25 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (5) and HR25 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (5) to (3) Voltage 4.9 to 5.1 V

Related circuit diagram

40-419

WA1200-6

40-419

Troubleshooting by failure code Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault

Failure code [DW4RKB] Bucket tilt EPC solenoid (1) ground fault
Action level E03 Failure code DW4RKB Failure Bucket tilt EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-420

Detail of failure Ground fault occurs in bucket tilt EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Bucket tilt speed is slow. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR25 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR25 (male) Between (1), (3) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective bucket Tilt EPC solenoid (1)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR25 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L07 Resistance Min. 1 Mz (female) (5) and HR25 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (5) to (3) Voltage 4.9 to 5.1 V

Related circuit diagram

40-420

40-420

WA1200-6

Troubleshooting by failure code Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short

Failure code [DW4RKY] Bucket tilt EPC solenoid (1) hot short
Action level E03 Failure code DW4RKY Failure Bucket tilt EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-421

Detail of failure Hot short circuit occurs in bucket tilt EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Bucket tilt speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR25 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR25 (male) Between (1), (3) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective bucket Tilt EPC solenoid (1)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR25 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L07 Voltage Max. 1 V (female) (5) and, HR25 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Voltage (5) to (3) 4.9 to 5.1 V

Related circuit diagram

40-421

WA1200-6

40-421

Troubleshooting by failure code Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection

Failure code [DW4SKA] Bucket dump1 EPC solenoid disconnection

Action level E03 Failure code DW4SKA Failure Bucket DUMP EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-42

Detail of failure Open circuit has occurred in bucket DUMP EPC solenoid (1) circuit Action of controller Problem on machine Related information No.
q

Bucket DUMP EPC solenoid (1) cannot be energized

Bucket DUMP speed is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR26 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR26 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective bucket DUMP EPC solenoid (1)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR26 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (15) and Resistance Max. 1 z HR26 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (15)(3) Voltage 4.95.1 V

Related circuit diagram

40-42

40-422

WA1200-6

Troubleshooting by failure code Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit

Failure code [DW4SKB] Bucket dump EPC solenoid (1) short circuit
Action level E03 Failure code DW4SKB Failure Bucket Dump EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-423

Detail of failure Ground fault occurs in bucket Dump EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Bucket Dump speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR26 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR26 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective bucket Dump EPC solenoid (1)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR26 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L07 Resistance Min. 1 Mz (female) (15) and HR26 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (15) to (3) Voltage 4.9 to 5.1 V

Related circuit diagram

40-423

WA1200-6

40-423

Troubleshooting by failure code Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short

Failure code [DW4SKY] Bucket dump EPC solenoid (1) hot short
Action level E03 Failure code DW4SKY Failure Bucket Dump EPC solenoid (1) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-424

Detail of failure Hot short circuit occurs in bucket Dump EPC solenoid (1) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Bucket Dump speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR26 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR26 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective bucket Dump EPC solenoid (1)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR26 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L07 Voltage Max. 1 V (female) (15) and HR26 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Voltage (15) to (3) 4.9 to 5.1 V

Related circuit diagram

40-424

40-424

WA1200-6

Troubleshooting by failure code Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection

Failure code [DW5PKA] Boom EPC solenoid (raise2) disconnection

Action level E03 Failure code DW5PKA Failure Boom RAISE EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-425

Detail of failure Open circuit has occurred in boom RAISE EPC solenoid (2) circuit Action of controller Problem on machine Related information No.
q

Boom RAISE EPC solenoid (1) cannot be energized

Boom RAISE speed is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR27 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR27 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective boom RAISE EPC solenoid (2)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR27 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (6) and HR27 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (6)(3) Voltage 4.95.1 V

Related circuit diagram

40-425

WA1200-6

40-425

Troubleshooting by failure code Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault

Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault
Action level E03 Failure code DW5PKB Failure Boom Raise EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-426

Detail of failure Ground fault occurs in boom Raise EPC solenoid (2) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom Raise speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR27 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting.

1 Defective frame angle sensor

HR27 (male) Between (1), (2) and ground Between (1) and (2)

Resistance Min. 1 Mz 5 to 15 kz

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR27 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L07 Resistance Min. 1 Mz (female) (6) and HR27 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (6) to (3) Voltage 4.9 to 5.1 V

Related circuit diagram

40-426

40-426

WA1200-6

Troubleshooting by failure code Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short

Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short
Action level E03 Failure code DW5PKY Failure Boom Raise EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-427

Detail of failure Hot short circuit occurs in boom Raise EPC solenoid (2) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom Raise speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR27 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting.

1 Defective frame angle sensor

HR27 (male) Between (1), (2) and ground Between (1) and (2)

Resistance Min. 1 Mz 5 to 15 kz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR27 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L07 Voltage Max. 1 V (female) (6) and HR27 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Voltage (6) to (3) 4.9 to 5.1 V

Related circuit diagram

40-427

WA1200-6

40-427

Troubleshooting by failure code Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection

Failure code [DW5QKA] Boom EPC solenoid (take down2) disconnection40-428

Action level E03 Failure code DW5QKA Failure Boom LOWER EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

Detail of failure Open circuit has occurred in boom LOWER EPC solenoid (2) circuit Action of controller Problem on machine Related information No.
q

Boom LOWER EPC solenoid (2) cannot be energized

Boom LOWER speed is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR28 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR28 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective boom LOWER EPC solenoid (2)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR28 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (16) and Resistance Max. 1 z HR28 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (16)(13) Voltage 4.95.1 V

Related circuit diagram

40-428

40-428

WA1200-6

Troubleshooting by failure code Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault

Failure code [DW5QKB] Boom Lower EPC solenoid (2) ground fault
Action level E03 Failure code DW5QKB Failure Boom Lower EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-429

Detail of failure Ground fault occurs in boom Lower EPC solenoid (2) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom Lower speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR28 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting.

1 Defective frame angle sensor

HR28 (male) Between (1), (2) and ground Between (1) and (2)

Resistance Min. 1 Mz 5 to 15 kz

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR28 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L07 Resistance Min. 1 Mz (female) (16) and HR28 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (16) to (13) Voltage 4.9 to 5.1 V

Related circuit diagram

40-429

WA1200-6

40-429

Troubleshooting by failure code Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short

Failure code [DW5QKY] Boom Lower EPC solenoid (2) hot short
Action level E03 Failure code DW5QKY Failure Boom Lower EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-430

Detail of failure Hot short circuit occurs in boom Lower EPC solenoid (2) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Boom Lower speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR28 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR28 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective boom Lower EPC solenoid (2)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR28 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness between L07 Voltage Max. 1 V (female) (16) and HR28 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Voltage (16) to (13) 4.9 to 5.1 V

Related circuit diagram

40-430

40-430

WA1200-6

Troubleshooting by failure code Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection

Failure code [DW5RKA] Bucket tilt2 EPC solenoid disconnection

Troubleshooting by failure code 40-431 WA1200-6

40-431

Action level E03

Failure code DW5RKA

Failure

Bucket TILT EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

Detail of failure Open circuit has occurred in bucket TILT EPC solenoid (2) circuit Action of controller Problem on machine Related information No.
q

Bucket TILT EPC solenoid (2) cannot be energized

Bucket TILT speed is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR29 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR29 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective bucket TILT EPC solenoid (2)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR29 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (25) and Resistance Max. 1 z HR29 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (25)(3) Voltage 4.95.1 V

Related circuit diagram

40-431

WA1200-6

40-431

Troubleshooting by failure code Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault

Failure code [DW5RKB] Bucket tilt EPC solenoid ground fault

Action level E03 Failure code DW5RKB Failure Bucket Tilt EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-432

Detail of failure Ground fault occurs in bucket Tilt EPC solenoid (2) circuit. Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Bucket tilt speed becomes slower. a Condition is restored if no failure code is displayed on monitor when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed and connecter is restored as troubleshooting is performed while failure is appearing. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR29 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. HR29 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 5 to 15 kz

Defective bucket Tilt EPC solenoid (2)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR29 and connect T-adapter. 3. Turn starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L07 Resistance Min. 1 Mz (female) (25) and HR29 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (25) to (3) Voltage 4.9 to 5.1 V

Related circuit diagram

40-432

40-432

WA1200-6

Troubleshooting by failure code Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short

Failure code [DW5RKY] Bucket tilt2 EPC solenoid hot short

Action level E03 Failure code DW5RKY Failure Bucket TILT EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-43

Detail of failure Hot short circuit has occurred in bucket TILT EPC solenoid (2) circuit Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Bucket TILT speed becomes slower a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR29 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR29 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective bucket TILT EPC solenoid (2)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR29 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with power supply circuit) Between ground and wiring harness from L07 Voltage Max. 1 V (female) (25) to HR29 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Voltage (25)(3) 4.95.1 V

Related circuit diagram

40-43

WA1200-6

40-433

Troubleshooting by failure code Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection

Failure code [DW5SKA] Bucket dump2 EPC solenoid disconnection

Action level E03 Failure code DW5SKA Failure Bucket DUMP EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-434

Detail of failure Open circuit has occurred in bucket DUMP EPC solenoid (2) circuit Action of controller Problem on machine Related information No.
q

Bucket DUMP EPC solenoid (2) cannot be energized

Bucket DUMP speed is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR30 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR30 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective bucket DUMP EPC solenoid (2)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR30 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L07 (female) (35) and Resistance Max. 1 z HR30 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (35)(3) Voltage 4.95.1 V

Related circuit diagram

40-434

40-434

WA1200-6

Troubleshooting by failure code Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit

Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit

Action level E03 Failure code DW5SKB Failure Bucket DUMP EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-435

Detail of failure Ground fault has occurred in bucket DUMP EPC solenoid (2) circuit Action of controller Problem on machine Related information No.
q

Bucket DUMP EPC solenoid (2) cannot be energized

Bucket DUMP speed is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR30 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR30 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective bucket DUMP EPC solenoid (2)

Ground fault in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR30 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Resistance Min. 1 Mz (female) (35) to HR30 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connectors to ON in turn, and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (35)(3) Voltage 4.95.1 V

Related circuit diagram

40-435

WA1200-6

40-435

Troubleshooting by failure code Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short

Failure code [DW5SKY] Bucket dump2 EPC solenoid hot short

Action level E03 Failure code DW5SKY Failure Bucket DUMP EPC solenoid (2) system error (input signal out of range) (Boom bucket & AJSS controller system)

40-436

Detail of failure Hot short circuit has occurred in bucket DUMP EPC solenoid (2) circuit Action of controller Problem on machine Related information No.
q

Turns the centralized warning lamp and alarm buzzer ON.

Bucket DUMP speed becomes slower a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR30 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. HR30 (male) Between (1), (2) and ground Between (1) and (2) Resistance Min. 1 Mz 515 kz

Defective bucket DUMP EPC solenoid (2)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR30 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L07 Voltage Max. 1 V (female) (35) to HR30 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connectors to ON in turn, and connect T-adapter. Defective boom bucket & AJSS 3. Turn starting switch to ON position and perform troubleshooting. 3 controller L07 (female) Voltage (35)(3) 4.95.1 V

Related circuit diagram

40-436

40-436

WA1200-6

Troubleshooting by failure code 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 level E03 Failure code DWJ2KA Failure R drain valve system error (Transmission controller system)

Detail of failure Open circuit has occurred in the R drain valve circuit Action of conR clutch drain valve solenoid output: OFF troller Problem on machine Related information No. R clutch disengaging time becomes longer a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T23 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 kz Min. 1 Mz

Defective R clutch drain valve solenoid

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between T23 (female) (2) and Max. 1 z ground Resistance Wiring harness between L04 (female) (37) and T23 Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L04 (female) Between (37) and ground Voltage during illuminance decrease adjustment

Related circuit diagram

40-437

WA1200-6

40-437

Troubleshooting by failure code Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit

Failure code [DWJ2KB] T/M E-POCV (R drain) Solenoid Short Circuit

Action level E03 Failure code DWJ2KB Failure R drain valve system error (Transmission controller system)

40-438

Detail of failure Ground fault has occurred in the R drain valve circuit Action of conR clutch drain valve solenoid output: OFF troller Problem on machine Related information No. R clutch disengaging time becomes longer a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T23 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 515 kz Min. 1 Mz

Defective R clutch drain valve solenoid

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L04 Resistance Max. 1 z (female) (37) to T23 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L04 (female) Between (37) and ground Voltage during illuminance decrease adjustment

Related circuit diagram

40-438

40-438

WA1200-6

Troubleshooting by failure code 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 E03 Failure code DWJ2KY Failure R drain valve system error (Transmission controller system)

Detail of failure Hot short circuit has occurred in the R drain valve circuit Action of conR clutch drain valve solenoid output: OFF troller Problem on machine Related information No. R clutch disengaging time becomes longer a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T23 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T23 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 kz Min. 1 Mz

Defective R clutch drain valve solenoid

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T23 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L04 Voltage Max. 1 V (female) (37) to T23 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller L04 (female) Voltage Between (37) and ground Max. 1V

Related circuit diagram

40-439

WA1200-6

40-439

Troubleshooting by failure code Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection

Failure code [DWM1KA] Work equipment neutral lock solenoid disconnection 40-4 0
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

Failure code DWM1KA

Failure

Work equipment neutral lock solenoid: Open circuit (Boom bucket & AJSS controller system)

Because of open circuit of work equipment neutral lock solenoid system, no current flows when work equipment neutral lock solenoid power output is turned ON. Stops outputting the signal from each work equipment EPC solenoid according to the input signal from the work equipment lock lever. If cause of failure disappears, machine becomes normal by itself. Each work equipment EPC solenoid lock for the work equipment lock lever works normally. Power output condition (ON/OFF) to work equipment neutral lock solenoid can be checked with monitoring function (Code: 40952, D-OUT-0). Method of reproducing failure code: Set the starting switch to ON position + Set the work equipment lock lever toLOCK position Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR22 and connect T-adapter. Defective work equipment neutral 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 lock solenoid HR22 (male) Resistance (Internal open circuit) Between (1) and (2) 3545 kz 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR22 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness 2 Wiring harness between L07 (female) (7) and HR22 Max. 1 z (open circuit or defective contact) (female) (1) Resistance Wiring harness between HR22 (female) (2) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Resistance Between (7) and ground 3545 kz

Related circuit diagram

40-4 0

40-440

WA1200-6

Troubleshooting by failure code Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit

Failure code [DWM1KB] Work equipment neutral lock solenoid short circuit
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

40-4 1

Failure code DWM1KB

Failure

Work equipment neutral lock solenoid: ground fault (Boom bucket & AJSS controller system)

Due to ground fault in work equipment neutral lock solenoid system, no current flows when work equipment neutral lock solenoid is energized. Stops outputting the signal from each work equipment EPC solenoid according to the input signal from the work equipment lock lever. If cause of failure disappears, machine becomes normal by itself. Each work equipment EPC solenoid lock for the work equipment lock lever works normally. Power output condition (ON/OFF) to work equipment neutral lock solenoid can be checked with monitoring function (Code: 40952, D-OUT-0). Method of reproducing failure code: Set the starting switch to ON position + Set the work equipment lock lever toLOCK position Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR22 and connect T-adapter. Defective work equipment neutral 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 lock solenoid HR22 (male) Resistance (Internal open circuit) Between (1) and (2) Ground fault in wiring harness (Contact with ground circuit) 3545 kz 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR22 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Resistance Max. 1 z (female) (7) to HR22 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. L07 (female) Between (7) and ground Resistance 3545 kz

Defective boom bucket & AJSS controller

Related circuit diagram

40-4 1

WA1200-6

40-441

Troubleshooting by failure code Failure code [DWM1KY] Work equipment neutral lock solenoid hot short

Failure code [DWM1KY] Work equipment neutral lock solenoid hot short40-4 2
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q

Failure code DWM1KY

Failure

Work equipment neutral lock solenoid: hot short circuit (Boom bucket & AJSS controller system)

Due to hot short circuit in work equipment neutral lock solenoid system, no current flows when work equipment neutral lock solenoid is energized. Stops outputting the signal from each work equipment EPC solenoid according to the input signal from the work equipment lock lever. If cause of failure disappears, machine becomes normal by itself. Each work equipment EPC solenoid lock for the work equipment lock lever works normally. Power output condition (ON/OFF) to work equipment neutral lock solenoid can be checked with monitoring function (Code: 40952, D-OUT-0). Method of reproducing failure code: Set the starting switch to ON position + Set the work equipment lock lever toLOCK position Cause Procedure, measuring location, criteria and remarks

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR22 and connect T-adapter. Defective work equipment neutral 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 lock solenoid HR22 (male) Resistance (Internal open circuit) Between (1) and (2) 3545 kz 1. Prepare with starting switch at OFF position. 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. Between ground and wiring harness from L07 ply circuit) Voltage Max. 1 V (female) (7) to HR22 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Defective boom bucket & AJSS 3 controller L07 (female) Resistance Between (7) and ground 3545 kz

Related circuit diagram

40-4 2

40-442

WA1200-6

Troubleshooting by failure code Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection

Failure code [DWN6KA] Magnet detent solenoid (Boom raise) disconnection 40-4 3
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q

Failure code DWN6KA

Failure

Lift arm RAISE magnet detent solenoid: Open circuit (Boom bucket & AJSS controller system)

When outputting current to lift arm RAISE magnet detent solenoid, no current flows due to open circuit in power supply circuit for lift arm RAISE magnet detent solenoid. Keeps outputting current to lift arm RAISE magnet detent solenoid normally. Stops outputting signal voltage to remote positioner RAISE stop pilot lamp. If cause of failure disappears, machine becomes normal by itself. The lift arm RAISE remote positioner does not work. Lift arm control lever is not held at RAISE detent position. Output (ON/OFF) to lift arm RAISE magnet detent solenoid can be checked by using monitoring function. (Code: 40952 D-OUT-1) Method of reproducing failure code: Start the engin + Set the lever to lift arm raise detent position Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S05 (male) Between (1) and (2) Resistance 3545 kz

Defective lift arm RAISE magnet 1 detent solenoid (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, S05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness 2 Wiring harness between L07 (female) (17) and S05 (open circuit or defective contact) Max. 1 z (female) (1) Resistance Wiring harness between S05 (female) (2) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS L07 Lift arm control lever Voltage 3 controller NEUTRAL position Max. 1 V Between (17) and ground Detent operation, RAISE 20 to 30 V

Related circuit diagram

40-4 3

WA1200-6

40-443

Troubleshooting by failure code Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit

Failure code [DWN6KB] Magnet detent solenoid (Boom raise) short circuit
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q

40-4 4

Failure code DWN6KB

Failure

Lift arm RAISE magnet detent solenoid: ground fault (Boom bucket & AJSS controller system)

Due to ground fault in lift arm RAISE magnet detent solenoid power supply system, no current flows when lift arm RAISE magnet detent solenoid is energized. Keeps outputting current to lift arm RAISE magnet detent solenoid normally. Stops outputting signal voltage to remote positioner RAISE stop pilot lamp. If cause of failure disappears, machine becomes normal by itself. The lift arm RAISE remote positioner does not work. Lift arm control lever is not held at RAISE detent position. Output (ON/OFF) to lift arm RAISE magnet detent solenoid can be checked by using monitoring function. (Code: 40952 D-OUT-1) Method of reproducing failure code: Start the engin + Set the lever to lift arm raise detent position Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S05 (male) Between (1) and (2) Resistance 3545 kz

Defective lift arm RAISE magnet 1 detent solenoid (Internal open circuit)

Ground fault in wiring harness (Contact with ground circuit)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, S05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Resistance Min. 1 Mz (female) (17) to S05 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 Between (17) and ground Lift arm control lever NEUTRAL position Detent operation, RAISE Voltage Max. 1 V 20 to 30 V

Related circuit diagram

40-4 4

40-444

WA1200-6

Troubleshooting by failure code Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short

Failure code [DWN6KY] Magnet detent solenoid (Boom raise) hot short 40-4 5
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q

Failure code DWN6KY

Failure

Lift arm RAISE magnet detent solenoid: hot short circuit (Boom bucket & AJSS controller system)

Due to hot short circuit in lift arm RAISE magnet detent solenoid power supply system, no current flows when lift arm RAISE magnet detent solenoid is energized. Keeps outputting current to lift arm RAISE magnet detent solenoid normally. Stops outputting signal voltage to remote positioner RAISE stop pilot lamp. If cause of failure disappears, machine becomes normal by itself. The lift arm RAISE remote positioner does not work. Lift arm control lever is not held at RAISE detent position. Output (ON/OFF) to lift arm RAISE magnet detent solenoid can be checked by using monitoring function. (Code: 40952 D-OUT-1) Method of reproducing failure code: Start the engin + Set the lever to lift arm raise detent position Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S05 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S05 (male) Between (1) and (2) Resistance 3545 kz

Defective lift arm RAISE magnet 1 detent solenoid (Internal open circuit)

1. Prepare with starting switch at OFF position. 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. Between ground and wiring harness from L07 ply circuit) Voltage Max. 1 V (female) (17) to S05 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS L07 Lift arm control lever Voltage 3 controller NEUTRAL position Max. 1 V Between (17) and ground Detent operation, RAISE 20 to 30 V

Related circuit diagram

40-4 5

WA1200-6

40-445

Troubleshooting by failure code Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection

Failure code [DWN7KA] Magnet detent solenoid (Boom float) disconnection 40-4 6
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q

Failure code DWN7KA

Failure

Lift arm FLOAT magnet detent solenoid: Open circuit (Boom bucket & AJSS controller system)

When outputting current to lift arm FLOAT magnet detent solenoid, no current flows due to open circuit in power supply circuit for lift arm FLOAT magnet detent solenoid. Keeps outputting current to lift arm FLOAT magnet detent solenoid normally. Stops outputting signal voltage to remote positioner LOWER stop pilot lamp. If cause of failure disappears, machine becomes normal by itself. The lift arm LOWER remote positioner does not work. Lift arm control lever is not held at FLOAT detent position. Output (ON/OFF) to lift arm FLOAT magnet detent solenoid can be checked by using monitoring function. (Code: 40952 D-OUT-2) Method of reproducing failure code: Start the engine + Set the lever to lift arm float detent position Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Resistance 3545 kz

Defective lift arm FLOAT magnet 1 detent solenoid (Internal open circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, S06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Open circuit in wiring harness 2 Wiring harness between L07 (female) (27) and S06 (open circuit or defective contact) Max. 1 z (female) (1) Resistance Wiring harness between S06 (female) (2) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS L07 Lift arm control lever Voltage 3 controller NEUTRAL position Max. 1 V Between (27) and ground FLOAT detent operation 20 to 30 V

Related circuit diagram

40-4 6

40-446

WA1200-6

Troubleshooting by failure code Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit

Failure code [DWN7KB] Magnet detent solenoid (Boom float) short circuit
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q

40-4 7

Failure code DWN7KB

Failure

Lift arm FLOAT magnet detent solenoid: ground fault (Boom bucket & AJSS controller system)

Due to ground fault in lift arm FLOAT magnet detent solenoid power supply system, no current flows when lift arm FLOAT magnet detent solenoid is energized. Keeps outputting current to lift arm FLOAT magnet detent solenoid normally. Stops outputting signal voltage to remote positioner LOWER stop pilot lamp. If cause of failure disappears, machine becomes normal by itself. The lift arm LOWER remote positioner does not work. Lift arm control lever is not held at FLOAT detent position. Output (ON/OFF) to lift arm FLOAT magnet detent solenoid can be checked by using monitoring function. (Code: 40952 D-OUT-2) Method of reproducing failure code: Start the engine + Set the lever to lift arm float detent position Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Resistance 3545 kz

Defective lift arm FLOAT magnet 1 detent solenoid (Internal open circuit)

1. Prepare with starting switch at OFF position. 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. Between ground and wiring harness from L07 cuit) Resistance Min. 1 Mz (female) (27) to S06 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS L07 Lift arm control lever Voltage 3 controller NEUTRAL position Max. 1 V Between (27) and ground FLOAT detent operation 20 to 30 V

Related circuit diagram

40-4 7

WA1200-6

40-447

Troubleshooting by failure code Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short

Failure code [DWN7KY] Magnet detent solenoid (Boom float) hot short 40-4 8
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q q

Failure code DWN7KY

Failure

Lift arm FLOAT magnet detent solenoid: hot short circuit (Boom bucket & AJSS controller system)

Due to hot short circuit in lift arm FLOAT magnet detent solenoid power supply system, no current flows when lift arm FLOAT magnet detent solenoid is energized. Keeps outputting current to lift arm FLOAT magnet detent solenoid normally. Stops outputting signal voltage to remote positioner LOWER stop pilot lamp. If cause of failure disappears, machine becomes normal by itself. The lift arm LOWER remote positioner does not work. Lift arm control lever is not held at FLOAT detent position. Output (ON/OFF) to lift arm FLOAT magnet detent solenoid can be checked by using monitoring function. (Code: 40952 D-OUT-2) Method of reproducing failure code: Start the engine + Set the lever to lift arm float detent position Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S06 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Resistance 3545 kz

Defective lift arm FLOAT magnet 1 detent solenoid (Internal open circuit)

1. Prepare with starting switch at OFF position. 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. Between ground and wiring harness from L07 ply circuit) Voltage Max. 1 V (female) (27) to S06 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS L07 Lift arm control lever Voltage 3 controller NEUTRAL position Max. 1 V Between (27) and ground FLOAT detent operation 20 to 30 V

Related circuit diagram

40-4 8

40-448

WA1200-6

Troubleshooting by failure code Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection

Failure code [DWN8KA] Magnet detent solenoid (Bucket tilt) disconnection 40-4 9
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q

Failure code DWN8KA

Failure

Bucket TILTmagnet detent solenoid: Disconnection (Boom bucket & AJSS controller system)

Due to open circuit in bucket TILT magnet detent solenoid power supply system, abnormal voltage exists when bucket TILT magnet detent solenoid is deenergized Stops outputting the signal to the bucket TILT magnet detent solenoid. If cause of failure disappears, machine becomes normal by itself. If the bucket TILT detent operation performed, the detent condition is not automatically released (can be manually released). 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). The output condition (ON/OFF) to the bucket TILT magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-3). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Between (1), (2) and ground Resistance 35 45 kz Min. 1 Mz

Defective bucket TILT magnet 1 detent solenoid (Internal short circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, S04 and connect T-adapter. Open circuit in wiring harness 2 3. Turn the starting switch to OFF position, then perform troubleshooting. (open circuit or defective contact) Wiring harness between L07 (female) (37) and S04 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS L07 Bucket lever Voltage 3 controller NEUTRAL position Max. 1 V Between (27) and ground Bucket detent 20 to 30 V operation

Related circuit diagram

40-4 9

WA1200-6

40-449

Troubleshooting by failure code Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit

Failure code [DWN8KB] Magnet detent solenoid (Boom tilt) short circuit40-450
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q

Failure code DWN8KB

Failure

Bucket TILT magnet detent solenoid: ground fault (Boom bucket & AJSS controller system)

Due to ground fault in bucket TILT magnet detent solenoid power supply system, abnormal voltage exists when bucket TILT magnet detent solenoid is deenergized Stops outputting the signal to the bucket TILT magnet detent solenoid. If cause of failure disappears, machine becomes normal by itself. If the bucket TILT detent operation performed, the detent condition is not automatically released (can be manually released). 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). The output condition (ON/OFF) to the bucket TILT magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-3). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Between (1), (2) and ground Resistance 3545 kz Min. 1 Mz

Defective bucket TILT magnet 1 detent solenoid (Internal short circuit)

Ground fault in wiring harness (contact with ground circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, S04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness between L07 Resistance Max. 1 z (female) (37) and S04 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 Between (27) and ground Bucket lever NEUTRAL position Bucket detent operation Voltage Max. 1 V 20 to 30 V

Defective boom bucket & AJSS controller

Related circuit diagram

40-450

40-450

WA1200-6

Troubleshooting by failure code Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short

Failure code [DWN8KY] Magnet detent solenoid (Boom tilt) hot short
Action level E03 Detail of failure Action of controller Problem on machine Related information No.
q q q q q q q

40-451

Failure code DWN8KY

Failure

Bucket TILT magnet detent solenoid: Short circuit to power supply line (Boom bucket & AJSS controller system)

Abnormal voltage appears when no current is output to the bucket tilt magnet detent solenoid due to hot short circuit in the bucket tilt magnet detent solenoid power supply system. Stops outputting the signal to the bucket TILT magnet detent solenoid. If cause of failure disappears, machine becomes normal by itself. If the bucket TILT detent operation performed, the detent condition is not automatically released (can be manually released). 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). The output condition (ON/OFF) to the bucket TILT magnet detent solenoid can be checked with the monitoring function (Code: 40952, D-OUT-3). Method of reproducing failure code: Start engine Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector S04 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Between (1), (2) and ground Resistance 3545 kz Min. 1 Mz

Defective bucket TILT magnet 1 detent solenoid (Internal short circuit)

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, S04 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness between L07 Voltage Max. 1 V (female) (37) and S04 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS L07 Bucket lever Voltage 3 controller NEUTRAL position Max. 1 V Between (27) and ground Bucket detent 20 to 30 V operation

Related circuit diagram

40-451

WA1200-6

40-451

Troubleshooting by failure code Failure code [DWNAKA] NC solenoid disconnection

Failure code [DWNAKA] NC solenoid disconnection

Troubleshooting by failure code 40-452 WA1200-6

40-452

Action level E01

Failure code DWNAKA

Failure

Modulation NC solenoid system error (Boom bucket & AJSS controller system)

Detail of failure Open circuit has occurred in the modulation NC solenoid (neutral cut solenoid) circuit Action of conNC solenoid output: OFF troller When there is an open circuit q Neutral cut control will not work (otherwise, no problem will appear on the machine) a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective neutral cut solenoid S06 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 kz Min. 1 Mz Problem on machine

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR1 and connect T-adapter. 3. Turn starting switch to ON position to perform troubleshooting. Wiring harness between L07 (female) (36) and Max. 1 z HR1 (female) (1) Resistance Wiring harness between HR1 (female) (2) and Max. 1 z ground 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Work equipment control Work equipment control L07 (female) lever operated (voltage) lever NEUTRAL (voltage) Between (36) and 1730 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)

Related circuit diagram

40-452

40-452

WA1200-6

Troubleshooting by failure code Failure code [DWNAKB] NC solenoid short circuit

Failure code [DWNAKB] NC solenoid short circuit

Action level E01 Failure code DWNAKB Failure Modulation NC solenoid system error (Boom bucket & AJSS controller system)

40-453

Detail of failure Ground fault has occurred in the modulation NC solenoid (neutral cut solenoid) circuit Action of conNC solenoid output: OFF troller When ground fault has occurred q Neutral cut control will not work (otherwise, no problem will appear on the machine) a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective neutral cut solenoid S06 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 515 kz Min. 1 Mz Problem on machine

Defective boom bucket & AJSS controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Resistance Min. 1 Mz (female) (36) to HR1 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Work equipment control Work equipment control L07 (female) lever operated (voltage) lever NEUTRAL (voltage) Between (36) and 1730 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)

Related circuit diagram

40-453

WA1200-6

40-453

Troubleshooting by failure code Failure code [DWNAKY] NC solenoid hot short

Failure code [DWNAKY] NC solenoid hot short

Action level E01 Failure code DWNAKY Failure Modulation NC solenoid system error (Boom bucket & AJSS controller system)

40-454

Detail of failure Hot short circuit has occurred in the modulation NC solenoid (neutral cut solenoid) circuit Action of controller Problem on machine
q

Detail of failure is displayed in yellow on the multi-monitor screen.

When there is a hot short circuit Rising of work equipment is slow a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor
q

No.

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR1 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting.

1 Defective neutral cut solenoid

S06 (male) Between (1) and (2) Between (1), (2) and ground

Resistance 515 kz Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L07, HR1 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L07 Voltage Max. 1 V (female) (36) to HR1 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Work equipment control Work equipment control L07 (female) Defective boom bucket & AJSS lever operated (voltage) lever NEUTRAL (voltage) 3 Between (36) and controller 1730 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)

Related circuit diagram

40-454

40-454

WA1200-6

Troubleshooting by failure code Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)

Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit) 40-45
Action level E03 Failure code DXA1KA Failure Work equipment pump solenoid valve system error (input signal out of range) (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 controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Defective work equipment pump solenoid valve Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR33 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Replace with a normally operating Failure code disappears solenoid valve 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR33 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L06 (female) (6) and HR33 Resistance Max. 1 z (female) (1) a Be ready with starting switch in OFF position, and perform troubleshooting without turning stating switch to ON position. Between ground and wiring harness from L06 Resistance Min. 1 Mz (female) (6) to HR33 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L06 (female) Between (6) and ground Resistance Min. 1 Mz
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Open circuit in wiring harness 2 (wire breakage or defective contact of connector) Open circuit in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

WA1200-6

40-455

Troubleshooting by failure code Failure code [DXA1KA] Loader pump solenoid Relay (Disconnect/Short Circuit)

Related circuit diagram

40-456

40-456

WA1200-6

Troubleshooting by failure code Failure code [DXA1KY] Loader pump solenoid Relay hot short

Failure code [DXA1KY] Loader pump solenoid Relay hot short

Action level E03 Failure code DXA1KY Failure Work equipment pump solenoid valve system error (input signal out of range) (Boom bucket & AJSS controller system)

40-457

Detail of failure Hot short circuit has occurred in work equipment pump solenoid valve circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks
q

Detail of failure is displayed in yellow on the multi-monitor screen.

1. Prepare with starting switch at OFF position. 2. Disconnect connector HR33 and connect T-adapter. Defective work equipment pump 1 3. Turn starting switch to ON position and perform troubleshooting. solenoid valve Replace with a normally operating Failure code disappears solenoid valve 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR33 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L06 Voltage Max. 1 V (female) (6) to HR33 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective boom bucket & AJSS 3 controller L06 (female) Resistance Between (6) and ground Min. 1 Mz

WA1200-6

40-457

Troubleshooting by failure code Failure code [DXA1KY] Loader pump solenoid Relay hot short

Related circuit diagram

40-458

40-458

WA1200-6

Troubleshooting by failure code Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)

Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit) 40-459
Action level E03 Failure code DXA1MA Failure Work equipment pump solenoid valve system error (input signal out of range) (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 controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Defective work equipment pump solenoid valve Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector HR33 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Replace with a normally operating Failure code disappears solenoid valve 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR33 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L06 (female) (6) and HR33 Resistance Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L06, HR33 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L06 Resistance Min. 1 Mz (female) (6) to HR33 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L06 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L06 (female) Between (6) and ground Resistance Min. 1 Mz
q

Detail of failure is displayed in yellow on the multi-monitor screen.

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Open circuit in wiring harness (contact with ground circuit)

Defective boom bucket & AJSS controller

WA1200-6

40-459

Troubleshooting by failure code Failure code [DXA1MA] Loader pump solenoid Relay (Disconnect/Short Circuit)

Related circuit diagram

40-460

40-460

WA1200-6

Troubleshooting by failure code Failure code [DXF0KA] AJSS EPC solenoid disconnection

Failure code [DXF0KA] AJSS EPC solenoid disconnection

Action level E03 Failure code DXF0KA Failure Steering source pressure EPC solenoid system error (Work equipment and joystick steering controller system)

40-461

Detail of failure Open circuit has occurred in steering source pressure control EPC solenoid circuit Action of conSteering source pressure control EPC solenoid output: OFF troller q Steering lever response becomes dull Problem on q Steering becomes slower q Steering lever response becomes sensitive machine q Steering becomes quicker a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor q Keep the joystick steering lever in the neutral position whenever it is not used. No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect R33 (solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 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) 1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector L07 and each connector to R33 to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. 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) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (23)(26) Check on multi monitor screen Current value 600 80 mA

Defective steering source pressure control EPC solenoid

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Defective work equipment and joystick steering controller

WA1200-6

40-461

Troubleshooting by failure code Failure code [DXF0KA] AJSS EPC solenoid disconnection

Related circuit diagram

40-462

40-462

WA1200-6

Troubleshooting by failure code Failure code [DXF0KB] AJSS EPC solenoid short circuit

Failure code [DXF0KB] AJSS EPC solenoid short circuit

Action level E03 Failure code DXF0KB Failure Steering source pressure EPC solenoid system error (Work equipment and joystick steering controller system)

40-463

Detail of failure Ground fault has occurred in steering source pressure control EPC solenoid circuit Action of conSteering source pressure control EPC solenoid output: OFF troller q Steering lever response becomes dull Problem on q Steering becomes slower q Steering lever response becomes sensitive machine q Steering becomes quicker a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor q Keep the joystick steering lever in the neutral position whenever it is not used. No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect R33 (solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 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) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L07 to R33 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L07 Min. 1 Mz (female) (6) to R33 (female) (2) Resistance Between ground and wiring harness from L07 Min. 1 Mz (female) (16) to R33 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L07 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L07 (female) (23)(26) Check on multi monitor screen Current value 600 80 mA

Defective steering source pressure control EPC solenoid

Ground fault in wiring harness (contact with ground circuit)

Defective work equipment and joystick steering controller

WA1200-6

40-463

Troubleshooting by failure code Failure code [DXF0KB] AJSS EPC solenoid short circuit

Related circuit diagram

40-464

40-464

WA1200-6

Troubleshooting by failure code Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection

Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection

Action level E03 Failure code DXH4KA Failure Transmission 1st solenoid system error (Transmission controller system)

40-465

Detail of failure Open circuit has occurred in transmission 1st solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T3 (1st solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 1st solenoid T3 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector L04 and each connector to be disconnected to T3 in turn. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective conWiring harness between L04 (female) (25) and T3 tact of connector) Max. 1 z (female) (1) Resistance Wiring harness between L04 (female) (13) and T3 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (25) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-465

Troubleshooting by failure code Failure code [DXH4KA] T/M E-POCV (1st) Solenoid Disconnection

Related circuit diagram

40-46

40-466

WA1200-6

Troubleshooting by failure code Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit

Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit

Action level E03 Failure code DXH4KB Failure Transmission 1st solenoid system error (Transmission controller system)

40-467

Detail of failure Ground fault has occurred in transmission 1st solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T3 (1st solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 1st solenoid T3 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T3 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L04 2 (contact with ground circuit) Min. 1 Mz (female) (13) to T3 (female) (2) Resistance Between ground and wiring harness from L04 Min. 1 Mz (female) (25) to T3 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (25) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-467

Troubleshooting by failure code Failure code [DXH4KB] T/M E-POCV (1st) Solenoid Short Circuit

Related circuit diagram

40-468

40-468

WA1200-6

Troubleshooting by failure code Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short

Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short
Action level E03 Failure code DXH4KY Failure Transmission 1st solenoid system error (Transmission controller system)

40-469

Detail of failure Hot short circuit has occurred in transmission 1st solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T3 (1st solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 1st solenoid T3 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T3 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L04 2 (contact with 24 V circuit) Max. 1 V (female) (13) to T3 (female) (2) Voltage Between ground and wiring harness from L04 Max. 1 V (female) (25) to T3 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (25) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-469

Troubleshooting by failure code Failure code [DXH4KY] T/M E-POCV (1st) Solenoid circuit Hot short

Related circuit diagram

40-470

40-470

WA1200-6

Troubleshooting by failure code Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection

Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection

Action level E03 Failure code DXH5KA Failure Transmission 2nd solenoid system error (Transmission controller system)

40-471

Detail of failure Open circuit has occurred in transmission 2nd solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T5 (2nd solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 2nd solenoid T5 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector L04 and each connector to be disconnected to T5 in turn. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective conWiring harness between L04 (female) (6) and T5 tact of connector) Max. 1 z (female) (1) Resistance Wiring harness between L04 (female) (3) and T5 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (6) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-471

Troubleshooting by failure code Failure code [DXH5KA] T/M E-POCV (2nd) Solenoid Disconnection

Related circuit diagram

40-472

40-472

WA1200-6

Troubleshooting by failure code Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit

Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit

Action level E03 Failure code DXH5KB Failure Transmission 2nd solenoid system error (Transmission controller system)

40-473

Detail of failure Ground fault has occurred in transmission 2nd solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T5 (2nd solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 2nd solenoid T5 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T5 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L04 2 (contact with ground circuit) Min. 1 Mz (female) (3) to T5 (female) (2) Resistance Between ground and wiring harness from L04 Min. 1 Mz (female) (6) to T5 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (6) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-473

Troubleshooting by failure code Failure code [DXH5KB] T/M E-POCV (2nd) Solenoid Short Circuit

Related circuit diagram

40-474

40-474

WA1200-6

Troubleshooting by failure code Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short

Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short
Action level E03 Failure code DXH5KY Failure Transmission 2nd solenoid system error (Transmission controller system)

40-475

Detail of failure Hot short circuit has occurred in transmission 2nd solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T5 (2nd solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 2nd solenoid T5 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T5 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L04 2 (contact with 24 V circuit) Max. 1 V (female) (3) to T5 (female) (2) Voltage Between ground and wiring harness from L04 Max. 1 V (female) (6) to T5 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (6) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-475

Troubleshooting by failure code Failure code [DXH5KY] T/M E-POCV (2nd) Solenoid circuit Hot short

Related circuit diagram

40-476

40-476

WA1200-6

Troubleshooting by failure code Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection

Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection

Action level E03 Failure code DXH6KA Failure Transmission 3rd solenoid system error (Transmission controller system)

40-47

Detail of failure Open circuit has occurred in transmission 3rd solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T7 (3rd solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 3rd solenoid T7 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector L04 and connectors to T7 to be disconnected in turn. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (16) and T7 Resistance Max. 1 z (female) (1) Wiring harness between L04 (female) (3) and T7 (female) (2) Max. 1 z

1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (16) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-477

Troubleshooting by failure code Failure code [DXH6KA] T/M E-POCV (3rd) Solenoid Disconnection

Related circuit diagram

40-478

40-478

WA1200-6

Troubleshooting by failure code Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit

Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit

Action level E03 Failure code DXH6KB Failure Transmission 3rd solenoid system error (Transmission controller system)

40-479

Detail of failure Ground fault has occurred in transmission 3rd solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T7 (3rd solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 3rd solenoid T7 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T7 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L04 2 (contact with ground circuit) Min. 1 Mz (female) (3) to T7 (female) (2) Resistance Between ground and wiring harness from L04 Min. 1 Mz (female) (16) to T7 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (16) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-479

Troubleshooting by failure code Failure code [DXH6KB] T/M E-POCV (3rd) Solenoid Short Circuit

Related circuit diagram

40-480

40-480

WA1200-6

Troubleshooting by failure code Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short

Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short
Action level E03 Failure code DXH6KY Failure Transmission 3rd solenoid system error (Transmission controller system)

40-481

Detail of failure Hot short circuit has occurred in transmission 3rd solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T7 (3rd solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective 3rd solenoid T7 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T7 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L04 2 (contact with 24 V circuit) Max. 1 V (female) (3) to T7 (female) (2) Voltage Between ground and wiring harness from L04 Max. 1 V (female) (16) to T7 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (16) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-481

Troubleshooting by failure code Failure code [DXH6KY] T/M E-POCV (3rd) Solenoid circuit Hot short

Related circuit diagram

40-482

40-482

WA1200-6

Troubleshooting by failure code Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection

Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection

Action level E03 Failure code DXH7KA Failure Transmission R solenoid system error (Transmission controller system)

40-483

Detail of failure Open circuit has occurred in transmission R solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T11 (R solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective R solenoid T11 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector L04 and connectors to T11 to be disconnected in turn. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective conWiring harness between L04 (female) (15) and T11 tact of connector) Max. 1 z (female) (1) Resistance Wiring harness between L04 (female) (13) and T11 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (15) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-483

Troubleshooting by failure code Failure code [DXH7KA] T/M E-POCV (R) Solenoid Disconnection

Related circuit diagram

40-484

40-484

WA1200-6

Troubleshooting by failure code Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit

Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit

Action level E03 Failure code DXH7KB Failure Transmission R solenoid system error (Transmission controller system)

40-485

Detail of failure Ground fault has occurred in transmission R solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T11 (R solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective R solenoid T11 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T11 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L04 2 (contact with ground circuit) Min. 1 Mz (female) (13) to T11 (female) (2) Resistance Between ground and wiring harness from L04 Min. 1 Mz (female) (15) to T11 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (15) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-485

Troubleshooting by failure code Failure code [DXH7KB] T/M E-POCV (R) Solenoid Short Circuit

Related circuit diagram

40-486

40-486

WA1200-6

Troubleshooting by failure code Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short

Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short
Action level E03 Failure code DXH7KY Failure Transmission R solenoid system error (Transmission controller system)

40-487

Detail of failure Hot short circuit has occurred in transmission R solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T11 (R solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective R solenoid T11 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T11 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L04 2 (contact with 24 V circuit) Max. 1 V (female) (13) to T11 (female) (2) Voltage Between ground and wiring harness from L04 Max. 1 V (female) (15) to T11 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (15) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-487

Troubleshooting by failure code Failure code [DXH7KY] T/M E-POCV (R) Solenoid circuit Hot short

Related circuit diagram

40-48

40-488

WA1200-6

Troubleshooting by failure code Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection

Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection

Action level E03 Failure code DXH8KA Failure Transmission F solenoid system error (Transmission controller system)

40-489

Detail of failure Open circuit has occurred in transmission F solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T13 (F solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective F solenoid T13 Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Connect T-adapter to connector L04 and connectors to T13 to be disconnected in turn. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. 2 (wire breakage or defective conWiring harness between L04 (female) (5) and T13 tact of connector) Max. 1 z (female) (1) Resistance Wiring harness between L04 (female) (3) and T13 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (5) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-489

Troubleshooting by failure code Failure code [DXH8KA] T/M E-POCV (F) Solenoid Disconnection

Related circuit diagram

40-490

40-490

WA1200-6

Troubleshooting by failure code Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit

Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit

Action level E03 Failure code DXH8KB Failure Transmission F solenoid system error (Transmission controller system)

40-491

Detail of failure Ground fault has occurred in transmission F solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T13 (F solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective F solenoid T13 Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T13 in turn and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Ground fault in wiring harness Between ground and wiring harness from L04 2 (contact with ground circuit) Min. 1 Mz (female) (13) to T13 (female) (5) Resistance Between ground and wiring harness from L04 Min. 1 Mz (female) (5) to T13 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (5) and ground When in NEUTRAL Max. 1 V

WA1200-6

40-491

Troubleshooting by failure code Failure code [DXH8KB] T/M E-POCV (F) Solenoid Short Circuit

Related circuit diagram

40-492

40-492

WA1200-6

Troubleshooting by failure code Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short

Failure code [DXH8KY] T/M E-POCV (F) Solenoid circuit Hot short
Action level E03 Failure code DXH8KY Failure Transmission F solenoid system error (Transmission controller system)

40-493

Detail of failure Hot short circuit has occurred in transmission F solenoid circuit Action of conNEUTRAL (all ECMV outputs: OFF) troller Problem on machine Related information No. Machine cannot travel a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect T13 (F solenoid) and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. 1 Defective F solenoid T13 Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

1. Prepare with starting switch at OFF position. 2. Disconnect connectors from L04 to T13 in turn and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Hot short circuit in wiring harness Between ground and wiring harness from L04 2 (contact with 24 V circuit) Max. 1 V (female) (3) to T13 (female) (2) Voltage Between ground and wiring harness from L04 Max. 1 V (female) (5) to T13 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller Directional selector L04 Voltage switch Between (5) and ground When in NEUTRAL Max. 1 V

Related circuit diagram

40-493

WA1200-6

40-493

Troubleshooting by failure code 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 level E03 Failure code DXHPKA Failure Transmission modulation clutch solenoid system error (Transmission controller system)

Detail of failure Open circuit has occurred in modulation clutch solenoid circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T9 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 kz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective modulation clutch ECMV solenoid

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T9 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Wiring harness between L04 (female) (23) and T9 Max. 1 z (female) (2) Resistance Wiring harness between L04 (female) (36) and T9 Max. 1 z (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L04 (female) Between (36) and ground Voltage Max. 1 V

Related circuit diagram

40-494

40-494

WA1200-6

Troubleshooting by failure code Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit

Failure code [DXHPKB] T/M E-POCV (MOD/C) Solenoid Short Circuit

Action level E03 Failure code DXHPKB Failure Modulation clutch solenoid system error (Transmission controller system)

40-495

Detail of failure Ground fault has occurred in modulation clutch solenoid circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T9 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Between (1), (2) and ground Ground fault in wiring harness (contact with ground circuit) Resistance 515 kz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective modulation clutch ECMV solenoid

3 Defective transmission controller

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T9 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. Between ground and wiring harness from L04 Resistance Min. 1 Mz (female) (36) to T9 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. L04 (female) Between (36) and ground Voltage Max. 1 V

Related circuit diagram

40-495

WA1200-6

40-495

Troubleshooting by failure code 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 level E03 Failure code DXHPKY Failure Modulation clutch solenoid system error (Transmission controller system)

Detail of failure Hot short circuit has occurred in modulation clutch solenoid circuit Action of controller Problem on machine Related information No. a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshooting, or when T-adapter is removed, connecter restored, and no failure code is displayed on the monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T9 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. S06 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 kz Min. 1 Mz
q

Turns the centralized warning lamp and alarm buzzer ON.

Defective modulation clutch ECMV solenoid

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T9 and connect T-adapter. Hot short circuit in wiring harness 2 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L04 Voltage Max. 1 V (female) (36) to T9 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. 3 Defective transmission controller L04 (female) Voltage Between (36) and ground Max. 1 V

Related circuit diagram

40-496

40-496

WA1200-6

Troubleshooting by failure code Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction

Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction

Action level E01
q q

40-497

Failure code DXHPMA

Failure

Modulation ECMV solenoid system error (Transmission controller system)

Detail of failure An open circuit, ground fault, or hot short circuit has occurred in the modulation ECMV solenoid circuit Action of controller Emergency spool operates Emergency operation switch: ON 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. q Travel speed cannot be controlled machine q Machine can travel in any gear speed a Condition is restored when connector is disconnected and T-adapter is inserted for troubleshootRelated inforing, or when T-adapter is removed, connecter restored, and no failure code is displayed on the mation monitor Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch at OFF position. 2. Disconnect connector T9 and connect T-adapter. 3. Turn the starting switch to OFF position, then perform troubleshooting. T9 (male) Between (1) and (2) Between (1), (2) and ground Resistance 515 z Min. 1 Mz

No.

Defective modulation clutch ECMV solenoid

1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T9 and connect T-adapter. Open circuit in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (wire breakage or defective con- Wiring harness between L04 (female) (36) and T9 Max. 1 z (female) (1) tact of connector) Resistance Wiring harness between L04 (female) (23) and T9 Max. 1 z (female) (2) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T9 and connect T-adapter. Ground fault in wiring harness 3. Turn the starting switch to OFF position, then perform troubleshooting. (contact with ground circuit) Between ground and wiring harness from L04 Resistance Min. 1 Mz (female) (36) to T9 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connectors L04, T9 and connect T-adapter. Hot short circuit in wiring harness 3. Turn starting switch to ON position and perform troubleshooting. (contact with 24 V circuit) Between ground and wiring harness from L04 Voltage Max. 1 V (female) (36) to T9 (female) (1) 1. Prepare with starting switch at OFF position. 2. Disconnect connector L04 and connect T-adapter. 3. Turn starting switch to ON position and perform troubleshooting. Defective transmission controller L04 (female) Voltage Between (36) and ground Max. 1 V

WA1200-6

40-497

Troubleshooting by failure code Failure code [DXHPMA] T/M E-POCV (MOD/C) Solenoid Malfunction

Related circuit diagram

40-498

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),

WA1200-6

E-1 Remote positioner "RAISE" or "LOWER" LED does not light up

Failure Related information No. Remote positioner "RAISE" or "LOWER" LED does not light up.
q q

40-49

40-49

Check that multi monitor operates normally. If fuse I (II) is blown, check wiring harness between fuse and L136 (female) (1) or L138 (female) (1) for ground fault. Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapters to L07 connector and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between L07 (female) (8) and S12 (female) (1) Between L07 (female) (18) and S12 (female) (3) Resistance Max. 1 z Max. 1 z be discon-

Cause

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

1. Prepare with starting switch OFF. 2. Connect T-adapters to connector L07 and each connector to 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) Resis(1) Between ground and L07 (female) (18) or S12 (female) tance (3) 1. Prepare with starting switch OFF. 2. Disconnect connector L07 and connect T-adapters. Defective work equipment and joy3 3. Turn the starting switch OFF, then carry out troubleshooting. stick steering controller Between chassis ground and each of L07 (female) (8) Resisand (18) tance

Min. 1 Mz Min. 1 Mz

Min. 1 Mz

Related circuit diagram

40-49

WA1200-6

40-499

Troubleshooting of electrical system (E-mode), E-2 Open circuit or ground fault in check lamp system

E-2 Open circuit or ground fault in check lamp system

Failure Related information No. Open circuit or ground fault in check lamp system Check lamp Lights up: Max 1 V q Goes out: 20 to 30 V
q

40-50

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapters to connector V1 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between V1 (female) (14) and RA10 (female) (2) Between V1 (female) (14) and RA11 (female) (2) Resistance Max. 1 z Max. 1 z

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Ground fault in wiring harness (Contact with ground circuit)

1. Prepare with starting switch OFF. 2. Connect T-adapter to V1 connector and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between V1 (female) (14) and RA10 (female) (2) Between V1 (female) (14) and RA11 (female) (2) Resistance Min. 1 Mz Min. 1 Mz

3 Defective VHMS controller

1. Prepare with starting switch OFF. 2. Disconnect connector V1 and connect T-adapter. 3. Turn the starting switch OFF, then carry out troubleshooting. ResisBetween V11 (female) (14) and chassis ground tance

Min. 1 Mz

Related circuit diagram

40-50

40-500

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Troubleshooting of electrical system (E-mode), E-3 Machine monitor does not operate

E-3 Machine monitor does not operate

Failure Machine monitor does not work. Related information Check that fuse No. 10 of fuse box I is not blown. No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapters to connector FC01 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC01 (female) (4) and each of FCL1 (female) ResisMax. 1 z (27) and LR2 (female) (7) tance 1. Prepare with starting switch OFF. 2. Disconnect connector FC01 and connect T-adapters. 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)

40-501

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

2 Defective machine monitor

Related circuit diagram

40-501

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40-501

Troubleshooting of electrical system (E-mode), E-4 Turn signal lamp does not light up

E-4 Turn signal lamp does not light up

Failure Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapters to connector FC02 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC02 (female) (7) and FCL1 Resistance Max. 1 z (female) (15) 1. Prepare with starting switch OFF. 2. Disconnect connector FC02 and connect T-adapters. 3. Turn starting switch to ON position and perform troubleshooting. Voltage switches Right turn Between FC02 (female) (7) and chassis between 0 V and signal lamp: ground 20 to 30 V ON (voltage) repeatedly. a) Right turn signal lamp does not light up.

40-502

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

2 Defective machine monitor

Failure Related information No.

b) Left turn signal lamp does not light up.

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapters to connector FC02 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC02 (female) (16) and FCL1 Resistance Max. 1 z (female) (14) 1. Prepare with starting switch OFF. 2. Disconnect connector FC02 and connect T-adapters. 3. Turn starting switch to ON position and perform troubleshooting. Voltage switches Left turn sigBetween FC02 (female) (16) and chassis between 0 V and nal lamp: ON ground 20 to 30 V (voltage) repeatedly.

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

2 Defective machine monitor

40-502

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Troubleshooting of electrical system (E-mode), E-4 Turn signal lamp does not light up

Related circuit diagram

40-503

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40-503

Troubleshooting of electrical system (E-mode), E-5 Defective parking lamp

E-5 Defective parking lamp

Failure Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connector T18 and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Parking brake Between T18 (female) (1) and (2) switch: ON Max. 1 z (resistance) 1. Prepare with starting switch OFF. 2. Connect T-adapters to connector FC02 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC04 (female) (1) and each of Max. 1 z FCL1 (33), FR2 (8), and T18 (female) (1) Resistance Between chassis ground and T18 (female) Max. 1 z (2), JT1 (7), or (2) 1. Prepare with starting switch OFF. 2. Disconnect connector FC04 and connect T-adapters. 3. Turn starting switch to ON position and perform troubleshooting. Parking brake Between FC04 (female) (1) and chassis switch: ON 20 to 30V ground (voltage) a) Parking lamp does not light up.

40-504

Defective parking brake indicator switch

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

3 Defective machine monitor

Failure Related information No.

b) Parking lamp does not go out.

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connector T18 and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Parking brake Between T18 (female) (1) and (2) switch: ON Min. 1 Mz (resistance) 1. Prepare with starting switch OFF. 2. Connect T-adapter to connector FC02 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC04 (female) (1) and each of Resistance Min. 1 Mz FCL1 (33), FR2 (8), and T18 (female) (1) 1. Prepare with starting switch OFF. 2. Disconnect connector FC04 and connect T-adapters. 3. Turn starting switch to ON position and perform troubleshooting. Parking brake Between and FC04 (female) (1) and chassis switch: OFF 02 V ground (voltage)

Defective parking brake indicator switch

Ground fault in wiring harness (Contact with ground circuit)

3 Defective machine monitor

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Troubleshooting of electrical system (E-mode), E-5 Defective parking lamp

Related circuit diagram

40-505

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40-505

Troubleshooting of electrical system (E-mode), E-6 Defective front working lamp

E-6 Defective front working lamp

Failure a) Neither pilot lamp on machine monitor nor front working lamp lights up. Related information Check for blown-out bulbs before troubleshooting. No. Cause Procedure, measuring location, criteria and remarks

40-506

1. Prepare with starting switch OFF. 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. Lamp lights up. Replace with other normal relay. 1. Prepare with starting switch OFF. 2. Disconnect connectors L60, FL1, and CL1, and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Between L60 (female) (2) and fuse III (2) Max. 1 z (female) (1) Between L60 (female) (1) and each of Resistance FL1 (female) (9), L60 (female) (3), and Max. 1 z CL1 (male) (1)

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Failure

b) Front working lamp lights up but pilot lamp on machine monitor does not light up.

Related information Check for blown-out bulbs before troubleshooting. No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connectors FC13 and L60, and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC13 (female) (12) and L60 Resistance Max. 1 z (female) (1)

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Failure

c) Pilot lamp on machine monitor lights up but front working lamp does not light up.

Related information Check for blown-out bulbs before troubleshooting. No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connectors L60, C27, and C28, and connect T-adapter. 3. Turn the starting switch OFF, then carry out troubleshooting. Between L60 (female) (3) and each of C27 Max. 1 z (female) (1) and C28 (female) (1) Resistance Between L60 (female) (1) and WORK3 Max. 1 z (female) (1)

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

40-506

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Troubleshooting of electrical system (E-mode), E-6 Defective front working lamp

Related circuit diagram

40-507

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40-507

Troubleshooting of electrical system (E-mode), E-7 Defective rear working lamp

E-7 Defective rear working lamp

Failure a) Neither pilot lamp on machine monitor nor rear working lamp lights up. Related information Check for blown-out bulbs before troubleshooting. No. Cause Procedure, measuring location, criteria and remarks

40-508

1. Prepare with starting switch OFF. 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. Lamp lights up. Replace with other normal relay. 1. Prepare with starting switch OFF. 2. Disconnect connectors L61, LR11, and CL1, and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Between L61 (female) (2) and fuse III (6) Resistance Between L61 (female) (1) and each of LR11 (female) (13) and LR1 (female) (13) Max. 1 z Max. 1 z

Open circuit in wiring harness 2 (wire breakage or defective contact of connector)

Failure

b) Rear working lamp lights up but pilot lamp on machine monitor does not light up.

Related information Check for blown-out bulbs before troubleshooting. No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connector FC03 and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC03 (female) (12) and L61 Resistance Max. 1 z (female) (2)

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Failure

c) Pilot lamp on machine monitor lights up but rear working lamp does not light up.

Related information Check for blown-out bulbs before troubleshooting. No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connectors L61, GR05, and GR06, and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Between L61 (female) (1) and each of Max. 1 z 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)

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

40-508

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Troubleshooting of electrical system (E-mode), E-7 Defective rear working lamp

Related circuit diagram

40-509

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40-509

Troubleshooting of electrical system (E-mode), E-8 Headlamp does not light up

E-8 Headlamp does not light up

Failure Related information No. Headlamp does not light up.
q q

40-510

Before troubleshooting, check bulb for breakage. Check fuse III (10) for breakage. If it is broken, check wiring harness between FC03 (female) (12) - fuse III (10) for ground fault. Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connectors FC3, GR03, and TURN, and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC03 (female) (12) and GR03 Max. 1 z (2) (female) (5) Resistance Between FC03 (female) (12) and TURN Max. 1 z (female) (A)

Cause

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

Related circuit diagram

40-510

40-510

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Troubleshooting of electrical system (E-mode), E-8 Headlamp does not light up

WA1200-6

40-511

Troubleshooting of electrical system (E-mode), 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 Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapters to connector FC02 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC02 (female) (18) and FCL1 (female) (7) ResisMax. 1 z or E04 (female) (5) tance 1. Prepare with starting switch OFF. 2. Disconnect connector FC02 and connect T-adapters. 3. Start engine and perform troubleshooting. during illuminance Between FC02 (female) (18) and chassis ground Voltage increase adjustment a) Service meter does not work.

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

2 Defective machine monitor

Failure Related information No.

b) Service meter works while engine is stopped.

Cause

Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapter to connector FC02 and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. during illumiBetween FC02 (female) (18) and FCL1 (female) nance Resistance (7) or E04 (female) (5) decrease adjustment 1. Prepare with starting switch OFF. 2. Disconnect connector FC02 and connect T-adapters. 3. Turn starting switch to ON position and perform troubleshooting. Left turn sigBetween FC02 (female) (18) and chassis ground nal lamp: ON 05 V (voltage)

Hot short circuit in wiring harness (contact with 24 V circuit)

2 Defective machine monitor

40-512

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Troubleshooting of electrical system (E-mode), E-9 Service meter does not work, or service meter works while engine is stopped.

Related circuit diagram

40-513

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40-513

Troubleshooting of electrical system (E-mode), E-10 Monitor panel controller does not sound buzzer

E-10 Monitor panel controller does not sound buzzer

Failure Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Connect T-adapter to connector FC01and each connector to be disconnected in turn. 3. Turn the starting switch OFF, then carry out troubleshooting. Between FC01 (female) (13) and L43 (female) (2) or ResisMax. 1 z between FC01 (female) (14) and L42 (female) (2) tance 1. Prepare with starting switch OFF. 2. Disconnect connectors L42 and L43 and connect T-adapters. 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. Monitor panel controller does not sound buzzer.

40-514

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

2 Defective machine monitor

3 See troubleshooting of monitor panel controller system.

Related circuit diagram

40-514

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Troubleshooting of electrical system (E-mode), E-10 Monitor panel controller does not sound buzzer

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40-515

Troubleshooting of electrical system (E-mode), E-11 Defective auto-greasing system

E-11 Defective auto-greasing system

Failure Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connectors S14 and GRE1, and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. Between S14 (female) (6) and GRE1 (female) (1) Resistance Max. 1 z 1. Prepare with starting switch OFF. 2. Disconnect connector S14 and connect T-adapters. 3. Turn starting switch to ON position and perform troubleshooting. Auto-greasing Between S14 (female) (6) and chassis ground switch: ON Max 3 V (voltage) a) Forced lubrication cannot work.

40-516

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

2 Defective machine monitor

3 See Operation and maintenance manual, "Handling the auto-greasing system". Failure Related information No. Cause Procedure, measuring location, criteria and remarks 1. Prepare with starting switch OFF. 2. Disconnect connectors FC02 and GRE1, and connect T-adapters. 3. Turn the starting switch OFF, then carry out troubleshooting. ResisBetween FC02 (female) (3) and GRE1 (female) (2) Max. 1 z tance 1. Prepare with starting switch OFF. 2. Disconnect connector FC02 and connect T-adapters. 3. Turn starting switch to ON position and perform troubleshooting. during illuminance Between FC02 (female) (3) and chassis ground Voltage increase adjustment b) Auto-greasing indicator lamp flashes rapidly (2 times/second).

Open circuit in wiring harness 1 (wire breakage or defective contact of connector)

2 Defective machine monitor

3 See Operation and maintenance manual, "Handling the auto-greasing system". Failure Related information No. Cause Procedure, measuring location, criteria and remarks c) Auto-greasing indicator lamp flashes slowly (1 times/second)

1 See Operation and maintenance manual, "Handling the auto-greasing system". FC02(3) Relationship between input signal 2 and display of auto-greasing indicator lamp L L H H Display Rapid flashing (2 times/second) Slow flashing (1 time/second) Off ON

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Troubleshooting of electrical system (E-mode), E-11 Defective auto-greasing system

Related circuit diagram

40-517

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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)

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 measured 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
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Item 1. Measuring standard values by using multi monitor 1) How to use multi monitor 2) Measuring PPC relief oil pressure using [Pm Clinic] 3) Measuring engine speed and work equipment relief oil pressure using [Real-time monitor]. 4) Measuring engine speed 2. Measuring standard values with manual Snapshot function 1) Measuring standard values using [Manual Snapshot] 2) Points to remember when using the manual Snapshot function

Reference document page 40-518 40-519 40-520 40-521 40-522 40-524 40-524 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 q q

Engine speed ---- Real-time monitor [Engine] -- Engine speed display Work equipment relief oil pressure ---- Real-time monitor [Load meter] -- Current pressure (boom (lift arm) bottom pressure) display PPC relief oil pressure ---- Pm Clinic menu -- PPC oil pressure display

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

1) How to use multi monitor Procedure for selecting to service mode and screen display

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

2) Measuring PPC relief oil pressure using [Pm Clinic] 1] On the service menu selecting screen, use the [F3] or [F4] switch to select Pm Clinic, and press the [F6] switch.

Pm Clinic item Page 1/4 1/4 1/4 1/4 2/4 2/4 2/4 2/4 2/4 Item name Engine speed Engine oil pressure Engine oil temperature Engine coolant temperature Engine speed Blowby pressure Boost pressure Exhaust gas temperature Ambient temperature Common rail pressure Torque converter oil temperature Torque converter inlet pressure Torque converter outlet pressure Transmission main pressure Transmission lubricating oil pressure Modulation clutch pressure Hydraulic oil temperature PPC pressure Hydraulic oil pressure S/T pump pressure F brake oil pressure R brake oil pressure Sampling time 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S Unit rpm kPa degC degC rpm kPa kPa degC degC MPa Detected components Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller VHMS Engine controller

2] The Pm Clinic screen is displayed. Press the [F5] switch to display page 4/4. The current working data values are displayed in real time. When the [F3] switch is pressed, the current data is held.

2/4 3/4 3/4 3/4 3/4 3/4 3/4 4/4 4/4 4/4 4/4 4/4 4/4

degC Main moniter MPa MPa MPa MPa MPa C MPa VHMS VHMS VHMS VHMS Transmission controller Main moniter

a When the [F5] switch is pressed, the page is advanced and the necessary data are displayed.

VHMS Work equipMPa ment controller MPa MPa MPa VHMS VHMS VHMS

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

3) Measuring engine speed and work equipment relief oil pressure using [Real-time monitor]

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

Measuring hydraulic stall speed Relieve the boom (lift arm) cylinder or bucket cylinder on the extraction side with engine at full speed, and measure the engine speed. Measuring torque converter + hydraulic stall speed 1] In the same way as "Measuring low idle and high idle speeds", display item "Engine speed" on the real-time monitor screen. 2] 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). 3] Set transmission auto/manual shift selector switch (3) to "ON (Manual)". a At this time, the gear shift mode is in "2nd". 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 position to release the brake. 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) Testing condition Low idle High idle Torque converter stall Hydraulic stall Full stall Standard value for new machine 625 675 1,850 1,950 1,800 2,000 1,800 2,000 1,650 2,000 Repair limit 575 725 1,800 2,000 1,700 2,000 1,700 2,000 1,550 2,000 (rpm) Testing condition Low idle High idle Torque converter stall Hydraulic stall Full stall Standard value for new machine 625 675 1,850 1,950 1,750 1,950 1,750 1,950 1,600 1,950 Repair limit 575 725 1,800 2,000 1,650 2,000 1,650 2,000 1,500 2,000

Engine MODE: fixed to E

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

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 analysis 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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor)

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.

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a Data captured with the Snapshot function No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Item Time (SMR) Time (GMT) Eng. Speed (Engine) Eng. SpeedTM Fuel inject Rail press. Blowby press. Boost press. Eng. oil temp. Eng. oil press. Eng. cool temp. Eng. temp. 1278L Eng. temp. 3456L Eng. temp. 1278R Eng. temp. 3456R Accelerator pedal PPC oil press. Unit h rpm rpm mm3/st MPa kPa kPa C kPa C C C C C % MPa MPa C mV mV MPa MPa deg MPa mV deg rpm km/h C rpm % MPa MPa MPa C MPa C Magnification 1,000 1 1 100 10 10 10 1 10 1 1 1 1 1 1 10 10 1 1 1 10 10 1 10 1 1 1 10 1 1 1 10 10 10 1 10 1 Data acquired from Main monitor KOMTRAX Plus Engine controller T/M controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller KOMTRAX Plus Work equipment controller Main monitor Work equipment controller Work equipment controller Main monitor Main monitor Main monitor Work equipment controller Work equipment controller Work equipment controller T/M controller T/M controller T/M controller Main monitor T/M controller T/M controller T/M controller KOMTRAX Plus KOMTRAX Plus Main monitor T/M controller T/M controller KOMTRAX Plus T/M controller

18 Hyd. oil press. 19 Hyd. oil temp. 20 Frame angle 21 Bucket pot. 1 22 Boom bottom press. 23 Boom head press. 24 Boom angle 25 S/T pump press. 26 AJSS Lever 27 Frame angle 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Shift indicator T/M output shaft speed Vehicle speed T/C oil temp. M/C output shaft speed M/C slip rate M/C oil press. F. brake charge oil press. R. brake charge oil press. Brake oil temp. Brake oil press. Brake switch R Air temp. Engine mode

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment hydraulic system, general

Work equipment hydraulic system, general

a The general structure of this section is shown below.
Item Work equipment oil pressure group Work equipment general function diagram 1. Walk-around check 1) Function diagram 2) Troubleshooting flow 3) Walk-around machine check 4) Visual check around hydraulic tank 1] Checking for looseness of hydraulic tank cap (oil stains around oil filler port) 2] Checking for missing gasket of hydraulic tank cap 3] Checking if transducer (if equipped) valve is closed 4] Checking and replacement of breather element 5] Cleaning and replacement of hydraulic oil central breather air element (if equipped) 6] Breather layout drawing 5) Checking oil level 1] Checking oil level in engine oil pan, and adding oil 2] Checking oil level in transmission, and adding oil 3] Checking oil level in hydraulic tank, and adding oil 2. Checking standard values by using KOMTRAX Plus (checking work equipment valve PPC group) 1) Function diagram 2) Troubleshooting flow 3) Checking engine speed RPM set ON/OFF switch RPM set idle-up/down selector switch 3. Checking of work equipment valves 1) Function diagram 2) Troubleshooting flow Measuring individual relief pressures of main valve and work equipment lift speed 4. Checking pump control PPC group 1) Function diagram 2) Troubleshooting flow 3) Layout of components Layout of coin filters at both ends of ES valve 4) Differential valve layout drawing 5) How to check abnormality record of neutral cut-off solenoid valve (NC valve) 6) How to disable pump control function to obtain maximum pump delivery when failure occurs in neutral cut-off solenoid valve (NC valve) 7) Testing and adjusting differential valve output oil pressure 8) Differential valve performance Reference document page 40-530 40-530 40-532 40-532 40-534 40-535 40-535 40-535 40-535 40-536 40-536 40-536 40-540 40-542 40-542 40-542 40-543 40-544 40-544 40-546 40-547 40-549 40-550 40-552 40-552 40-554 40-555 40-556 40-556 40-558 40-559 40-559 40-560 40-561 40-562 40-563 40-566

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment hydraulic system, general

Item 5. Checking pump control PV group 1) Function diagram 2) Troubleshooting flow 3) Layout of components 4) Testing and adjusting PV control relief valve oil pressure 6. Checking No. 1 work equipment pump, No. 2 work equipment pump, sub pump group 1) Function diagram 2) Troubleshooting flow 3) Layout of components Layout of high-pressure line filter components 7. Checking No. 1 work equipment pump, No. 2 work equipment pump, main pump group 1) Function diagram 2) Troubleshooting flow 3) Pump CO (cut-off) performance 4) Pump checking procedure 5) Testing and adjusting work equipment pump CO (cut-off) valve oil pressure No. 1 work equipment pump No. 2 work equipment pump Switch pump 8. Checking steering pump, switch pump group 1) Function diagram 2) Troubleshooting flow

Reference document page 40-568 40-568 40-570 40-571 40-571 40-574 40-574 40-576 40-577 40-577 40-580 40-580 40-582 40-583 40-585 40-586 40-586 40-588 40-590 40-592 40-592 40-594

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40-529

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

Work equipment oil pressure group

Work equipment general function diagram [Troubleshooting method for work equipment oil pressure group] 1. Perform troubleshooting by judging the groups of related components in sequence.

40-530
40-530

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

1. Walk-around check 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-532 40-532

40-532

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40-533

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

2) Troubleshooting flow Contents of work (1) Walk-around check ... Around machine/around hydraulic tank/oil level check

40-534

Refer to page A: 40-535 B: 40-535, 538 D: 40-542 E: 40-544

40-534

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

3) Walk-around machine check Check for oil leaks from hydraulic piping around and inside the machine.

40-535

4) Visual check around hydraulic tank 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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40-537

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

4] Checking and replacement of breather element Check the appearance of breather and filter element.

40-538

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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40-539

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

6] Breather layout drawing

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-542 5) Checking oil level 1] Checking oil level in engine oil pan, and adding oil k Immediately after the engine is stopped, its parts and oil is still be very hot and you may be scalded. Wait until their temperature drops before starting the work. a When checking with the engine stopped, wait for at least 15 minutes after stopping the engine, and check the oil level. a When checking, park the machine on a level 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).

2] Checking oil level in transmission, and adding oil k Immediately after the engine is stopped, its parts and oil are still very hot. Therefore, wait until their temperature drops before starting the work. a Before starting the engine, make sure that the oil level is within upper A or between upper A and lower B of sight gauge (G). 1. Start the engine and run it at low idle. 2. Remove the cap of oil filler port (F).

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.

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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 adding oil k Immediately after the engine is stopped, its 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 slowly to release the internal pressure, then remove 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.

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40-543

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

2. Checking standard values by using KOMTRAX Plus (checking work equipment valve PPC group) 40-54 1) Function diagram 40-54 a Check portions shown with hatched lines in the drawing.

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40-545

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-546 2) Troubleshooting flow 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

3) Checking engine speed 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.

40-547

Refer to page A: 40-519, 520 B: 40-521, 522 C: 40-549, 550

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

Standard value (1) (Engine speed, work equipment speed)

Standard value for new machine Fixed to AUTO or P Engine speed Low idle (rpm) High idle Hydraulic relief At torque converter stall Full stall Work equipment speed Boom (lift arm) RAISE time (at high idle) Boom (lift arm) LOWER time (sec) Ground tilting time No load Dumping time 625 675 1,850 1,950 1,800 2,000 1,800 2,000 1,650 2,000 12.5 0.5 5.0 0.5 2.3 0.3 3.7 0.3 Fixed to E 625 675 1,850 1,950 1,750 1,950 1,750 1,950 1,600 1,950 13.7 0.5 5.0 0.5 2.5 0.3 3.7 0.3

(2) Stall speed

Standard value for new machine Fixed to Fixed to E AUTO or P At torque converter stall Engine speed
q

Repair limit Fixed to AUTO or P Fixed to E

Hydraulic stall
q

At torque converter stall and Hydraulic stall

Coolant: Within operating 1,800 2,000 1,750 1,950 1,700 2,000 1,650 2,000 range Torque converter oil temperature: 60 to 80 C rpm 1,800 2,000 1,750 1,950 1,700 2,000 1,650 2,000 Hydraulic oil temperature: 45 to 55 C 1,650 2,000 1,600 1,950 1,550 2,000 1,500 2,000 Gear shift lever: F4 or R4

40-548

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

RPM set ON/OFF switch (1) 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)

40-549

40-549 Supplementary explanation 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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-5 0 RPM set idle-up/down selector switch (2) 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 selector 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, indicator lamp lights up. This switch is used for maintaining a desired engine speed. (R.H. switch panel)

Position (c): This is used when setting the engine speed or increasing the set speed. q Using the accelerator pedal Depress the accelerator pedal and press portion (c) of switch at the desired engine speed. The speed is stored and set. q Using the RPM set idle-up/down switch When portion (c) of switch is pressed and held down for longer than 0.5 sec. the engine speed increases. Release the switch at the desired speed. The new speed is stored and set. Position (d): This is used when decreasing the set the engine speed, or recover the RPM set switch after it has 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. 40-5 0 Supplementary explanation

Setting engine speed with the RPM set switch is advantageous because excessive lowering in engine speed can be avoided during work using the accelerator pedal. The engine response will be better and the cycle time of work can be reduced. Since the travel speed can be maintained constant while travelling for load-and-carry operation, the operator's fatigue can be reduced. If resetting the engine speed to a desired speed without using portion (d) of the RPM set idle-up/down selector switch, depress the right brake pedal to cancel the set speed, and then depress the accelerator pedal to increase the engine speed. Depress setting side (c) of the switch at the desired speed. The new speed is stored and set.

40-550

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40-551

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

3. Checking of work equipment valves 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-5 2 40-5 2

40-552

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-5 4 2) Troubleshooting flow 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 B: 40-555 C: 40-519 D: 40-521 E: 40-523

F: 40-555 G: 40-563, 564 H: 40-563, 564 I: 40-555 J: 40-555

40-554

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

Measuring individual relief pressures of main valve and work equipment lift speed 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. Disconnect PPC circuit for other than the No. 2 valve. 4. Similarly, measure the relief pressure and work equipment speed on the No. 3 valve. Disconnect PPC circuit for other than the No. 3 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)

40-5 5

Standard value
Reference All valves No. 1 valve No. 2 valve No. 3 valve Main relief oil pressure (at stroke end) Boom (lift arm) RAISE speed (at no load) MPa sec 30 to 32 12 to 24 No. 1 valve (left) No. 2 valve (cen- No. 3 valve only ter) only (right) only 30 to 32 41 to 44 30 to 32 33 to 35 30 to 32 41 to 44

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

4. Checking pump control PPC group 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-5 6 40-5 6

40-556

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40-557

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-5 8 2) Troubleshooting flow 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 B: 40-521, 522 C: 40-561 D: 40-559 E: 40-562

F: 40-562 G: 40-563, 564 H: 40-565, 566 I: 40-566

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

3) Layout of components

40-5 9

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40-559

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

4) Differential valve layout drawing

40-560

40-560

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

6) How to disable pump control function to obtain maximum pump delivery when neutral cut-off sole40-562 noid valve (NC valve) fails 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

7) Testing and adjusting differential valve output oil pressure a Testing tools
Symbol 1 C Part No. 799-101-5002 Part name Oil pressure gauge kit (analog) (pressure gauge: 6 MPa {60 kg/cm2}) Oil pressure gauge kit (digital) q Nipple q Adapter

40-563

790-261-1204 2 799-101-5160 4 799-261-1311

Testing condition 40-563 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Stop the engine, then loosen the oil filler cap to release the pressure in the hydraulic tank.
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 equipment pump (2).

40-563 Testing 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 P1 port and hose (6) from P2 port of the ES valve. Install adapters C4 and nipples C2 and reconnect hoses (5) and (6).

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 {60 kg/cm2}) to nipple C2.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-564

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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.
q

40-565 Adjusting 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.

Standard values for pressure difference between P1 and P2 ports

Oil pressure (MPa {kg/cm2}) P1 port P2 port 3.7 to 3.9 {38 to 40} 4.3 to 4.9 {44 to 50} 3.7 to 3.9 {38 to 40} 4.9 to 5.5 {50 to 56} Differential pressure (MPa {kg/cm2}) 0 0.5 to 0.6 {5 to 6}

Engine speed Low idle (625 675 rpm) High idle (1,850 1,950 rpm)

3) Remove plug (7), and add or remove shims (8). a When adjusting by using shims for the differential 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).

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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

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40-567

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

5. Checking pump control PV group 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-568 40-568

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40-569

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

2) Troubleshooting flow Contents of work (1) Measure the engine speed by using KOMTRAX Plus. (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.

40-570

Refer to page A: 40-519 B: 40-521, 522

C: 40-569, 571 D: 40-569, 571, 572

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

3) Layout of components

40-571

4) Testing and adjusting PV control relief valve 40-571 oil pressure a Testing tools
Symbol 1 C Part No. 799-101-5002 Part name Oil pressure gauge kit (analog) (pressure gauge: 6 MPa {60 kg/cm2}) Oil pressure gauge kit (digital) q Nipple q Nipple

790-261-1204 2 799-101-5160 3 790-261-1311

Testing condition 40-571 q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine 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 equipment pump. PV valve set pressure: 2.9 MPa {30 kg/cm2}

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-572 Testing 1. Stop the engine. k Operate the work equipment control lever to release the pressure from the work equipment PPC accumulator. 2. Remove plug (2) (PT1/8) from block (1), install nipple C2, and then connect oil pressure gauge C1(6 MPa {60 kg/cm2}).

Adjusting 40-572 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 turn adjustment screw (5) to adjust the pressure. a Turn the adjustment screw clockwise to increase the set pressure, and turn it counterclockwise to decrease the pressure. a Pressure adjustment per one turn of adjustment 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}

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40-573

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

6. Checking loader pump, No. 1 work equipment pump, No. 2 work equipment pump, sub pump group40-574 1) Function diagram 40-574 a Check portions shown with hatched lines in the drawing.

40-574

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40-575

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-576 2) Troubleshooting flow Contents of work (1) Measure the engine speed by using KOMTRAX Plus. (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 B: 40-519 C: 40-521, 522 D: 40-578 E: 40-586 F: 40-585

G: 40-596, 597, 598 H: 40-587 I: 40-555 J: 40-589 K: 40-588, 589 L: 40-588, 589

40-576

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3) Layout of components Layout of high-pressure line filter components

40-57

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40-577

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-578

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

7. Checking No. 1 work equipment pump, No. 2 work equipment pump, main pump group 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-580 40-580

40-580

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40-581

Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-582 2) Troubleshooting flow Contents of work (1) Measure the engine speed by using KOMTRAX Plus. (2) Check the high-pressure line filter. If metallic powder (material worn off from pump) is found, replace pump. (3) On No. 1 valve only, measure work equipment relief pressure and boom (lift arm) RAISE speed with no load on bucket.

Refer to page A: 40-519, 520, 521 B: 40-577 C: 40-596, 597, 598

D: 40-555 E: 40-596, 597, 598 F: 40-586

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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 delivery.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-584

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

4) Pump checking procedure 40-585 (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).

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-586 5) Testing and adjusting work equipment pump CO (cut-off) valve oil pressure a Testing tools 40-586 No. 1 work equipment pump 1. Preparation Symbol Part No. Part name 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 equip799-101-5002 1 {60 kg/cm2}, 40 MPa ment pump. 2}) 2) Install joint C3 and nipple C2 of the oil pres{400 kg/cm 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 C2. 4 790-261-1311 q Adapter 3) Remove cover (1a) at the top of No. 1 work equipment pump (1). 40-586 Testing condition q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Stop the engine, then loosen the oil filler cap to release the pressure in the hydraulic tank. a To test the oil pressures of the work equipment pump CO valves, measure the delivery pressures of No. 1 work equipment pump (1) and No. 2 work equipment pump (2), and the output pressures of CO valves (4), (5), and (6) installed on each pump at ports on the servo valve side.

40-586

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

4) Remove CO+NC valve output pressure port plug (9) on rear servo valve (8) of No. 1 work equipment pump (1). 5) Install joint C3 and nipple C2 of the oil pressure 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. 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 the pressures by loosening lock nut (10) for CO+NC valve (4) and turning adjustment 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})

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

3. Adjusting CO valve pressure 1) Adjust the pressures by loosening lock nut (10) for CO+NC valve (4) and turning adjustment screw (11) by using a screwdriver. a To raise the cut-off, turn adjustment screw (11) clockwise. To lower the cut-off, turn it counterclockwise. Repeat the procedure until the correct set pressure 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}.

No. 2 work equipment pump 40-58 1. Preparation 1) Remove the front side pump delivery pressure pickup plug (11) on the No. 2 pump. 2) Install joint C3 and nipple C2 of the oil pressure gauge kit, and connect oil pressure gauge C1 (40 MPa {400 kg/cm2}) to nipple C2.

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 {60 kg/cm2}) to nipple C2.

2) After adjustment is completed, remove the joint and nipple of the oil pressure gauge kit and restore the machine.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

2. Testing CO valve oil pressure 1) With the engine running at low idle (650 rpm) and the bucket slowly moved to TILT end, read the No.2 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})

3. Adjusting CO valve pressure 1) Adjust by loosening lock nut (16) for CO+NC valve (5) and turning adjustment screw (17) by using a screwdriver. a To raise the cut-off, turn adjustment screw (17) clockwise. To lower the cut-off, turn it counterclockwise. Repeat the procedure until the correct set pressure is obtained. a Turning in the adjustment screw one turn will increase the No. 2 work equipment pump delivery pressure by 4.1 MPa {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. q CO valve output pressure standard value: 0.74 MPa {7.6 kg/cm2} a Increase the engine speed if the No. 2 work equipment pump delivery pressure does not reach 25.5 MPa {260 kg/cm2}.

2) After adjustment is completed, remove the joint adapter and nipple of the oil pressure gauge kit and restore the machine.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-590 Switch pump a Do not operate steering. 1. Preparation 1) Remove the front side pump delivery pressure pickup plug (18) on the switch pump. 2) Install joint C3 and nipple C2 of the oil pressure gauge kit, and connect oil pressure gauge C1 (40 MPa {400 kg/cm2}) to nipple C2.

2. Testing CO valve oil pressure 1) With the engine running at low idle (650 rpm) and the bucket slowly moved to TILT end, read the switch 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})

3) Remove CO+NC valve output pressure port plug (20) on servo valve (19) at the front side of the switch pump. 4) Install joint C3 and nipple C2 of the oil pressure gauge kit, and connect oil pressure gauge C1 (6 MPa {60 kg/cm2}) to nipple C2.

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 29.4 MPa {300 kg/cm2} as the bucket lever on the work equipment is slowly moved to TILT to increase the switch pump delivery pressure. q CO valve output pressure standard value: 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

3. Adjusting CO valve pressure 1) Adjust the pressures by loosening lock nut (21) for CO+NC valve (6) and turning adjustment 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 pressure is obtained. a Turning in the adjustment screw one turn will increase the switch pump delivery pressure by 4.1 MPa {41.3 kg/cm2}.

2) After adjustment is completed, remove the joint adapter and nipple of the oil pressure gauge kit and restore the machine.

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

8. Checking steering pump, switch pump group 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-592 40-592

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

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Troubleshooting of hydraulic and mechanical system (H-mode) Work equipment oil pressure group

40-594 2) Troubleshooting flow Contents of work (1) Measure the engine speed by using KOMTRAX Plus. (2) Check the high-pressure line filter. If metallic powder (material worn off from pump) is found, replace pump. (3) On No. 3 valve only, measure work equipment relief pressure and boom (lift arm) RAISE speed with no load on bucket.

Refer to page A: 40-519 B: 40-521, 522 C: 40-587, 588, 589 D: 40-555 E: 40-596, 597, 598

F: 40-577 G: 40-555 H: 40-586 I: 40-586 J: 40-585

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Troubleshooting of hydraulic and mechanical system (H-mode) 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 measured 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
Item 1. Measuring standard values by using multi monitor 1) How to use multi monitor 2) Measuring PPC relief pressure using [Pm Clinic] 3) Measuring engine speed and work equipment relief oil pressure using [Real-time monitor]. 4) Measuring engine speed 2. Measuring standard values with manual Snapshot function 1) Measuring standard values using [Manual Snapshot] 2) Points to remember when using the manual Snapshot function 3) Measuring input current to EPC valve using [Real-time monitor]. 4) Measuring steering pump outlet pressure using [Pm Clinic] 5) Measuring potentiometer output voltage using [Real-time monitor]. Reference document page 40-595 40-596 40-597 40-598 40-599 40-599 40-599 40-602 40-603 40-605 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 q q

Engine speed ---- Real-time monitor [Engine] -- Engine speed display Work equipment relief pressure ---- Real-time monitor [Work equipment] -- Current pressure (boom (lift arm) bottom pressure) display PPC relief oil pressure ---- Pm Clinic menu -- PPC oil pressure display

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

1) How to use multi monitor Displaying SERVICE MENU SELECT screen

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

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 Pag Item name e 1/4 Engine speed Engine oil pressure Engine oil tem1/4 perature Engine coolant 1/4 temperature 1/4 2/4 Engine speed Blowby pres2/4 sure 2/4 Boost pressure 2/4 2/4 2/4 3/4 3/4 Exhaust gas temperature Ambient temperature Common rail pressure Torque converter oil temperature Torque converter inlet pressure Sampling time 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S Unit rpm kPa degC degC rpm kPa kPa degC degC MPa Detected components Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller KOMTRAX Plus controller Engine controller Torque con3/4 verter outlet pressure Transmission 3/4 main pressure Transmission 3/4 lubricating oil pressure Modulation 3/4 clutch pressure Hydraulic oil 4/4 temperature 4/4 PPC pressure 4/4 Hydraulic oil pressure S/T pump pres4/4 sure F brake oil pres4/4 sure R brake oil 4/4 pressure 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S MPa MPa MPa MPa C MPa MPa MPa MPa MPa KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller Transmission controller Main moniter KOMTRAX Plus controller Work equipment controller KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller

degC Main moniter MPa KOMTRAX Plus controller

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

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.

Measuring torque converter + hydraulic stall speed 1] In the same way as "Measuring low idle and high idle speeds", display item "Engine speed" on the real-time monitor screen. 2] Set transmission cut-off switch (1) to OFF and depress left brake (4) securely (make sure that transmission cut-off pilot lamp (2) is off). 3] Set transmission auto/manual shift selector switch (3) to "ON (Manual)". a At this time, the gear shift mode is in "2nd". 4] Press the upshift switch 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 the forward and reverse (FNR) switch in "F" or "R". 6] Set parking brake switch (5) to the OFF position to release the brake. 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) Testing condition Low idle High idle Torque converter stall Hydraulic stall Full stall Standard value for new machine 625 675 1,850 1,950 1,800 2,000 1,800 2,000 1,650 2,000 Repair limit 575 725 1,800 2,000 1,700 2,000 1,700 2,000 1,550 2,000 (rpm) Testing condition Low idle High idle Torque converter stall Hydraulic stall Full stall Standard value for new machine 625 675 1,850 1,950 1,750 1,950 1,750 1,950 1,600 1,950 Repair limit 575 725 1,800 2,000 1,650 2,000 1,650 2,000 1,500 2,000

Measuring hydraulic stall speed Relieve the boom (lift arm) cylinder or bucket cylinder on the extraction side with engine at full speed, and measure the engine speed.

Engine MODE: fixed to E

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 analysis by using the manual Snapshot function of the multi monitor. a See page 20-1001-2-7 for points to remember when using this function. 40-599

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

1] Select [Snapshot] on the SERVICE MENU SELECT screen.

2] The Snapshot screen appears.

3] Capture the data.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

4] Capturing screen

5] Capturing screen

6] The Snapshot screen appears again.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

Work equipment controller Displayed page 1/9 1/9 1/9 2/9 2/9 2/9 2/9 3/9 3/9 3/9 3/9 4/9 4/9 4/9 4/9 5/9 5/9 5/9 5/9 5/9 6/9 6/9 6/9 6/9 6/9 7/9 7/9 7/9 7/9 7/9 7/9 8/9, 9/9 Software No. Software application version Software application data version Boom (lift arm) Raise EPC Current 1 Boom (lift arm) Raise EPC Current 2 Boom (lift arm) Lower EPC Current 1 Boom (lift arm) Lower EPC Current 2 Bucket Tilt EPC Current 1 Bucket Tilt EPC Current 2 Bucket Dump EPC Current 1 Bucket Dump EPC Current 2 Lever potentiometer voltage boom (lift arm) 1 Lever potentiometer voltage boom (lift arm) 2 Lever potentiometer voltage bucket 1 Lever potentiometer voltage bucket 2 Boom (lift arm) angle Boom (lift arm) angle Boom (lift arm) lever operation frequency Bucket lever operation frequency Pump delivery AJSS lever operation angle AJSS lever potentiometer voltage Boom (lift arm) angle AJSS frame potentiometer voltage AJSS EPC Current Loader pump pressure Loader pump pressure Boom (lift arm) bottom pressure Boom (lift arm) bottom pressure AJSS S/T deviation angle Digging-in-progress flag Input/Output signal Signal name Unit ------1 mA 1 mA 1 mA 1 mA 1 mA 1 mA 1 mA 1 mA 0.01 V 0.01 V 0.01 V 0.01 V 0.1 deg 0.01 V 1 cc 0.1 deg 0.01 V 0.1 deg 0.01 V 1 mA 0.01 MPa 0.001 V 0.01 MPa 0.001 V 0.1 deg 1: ON (digging) 0: OFF 1: ON 0: OFF(OPEN) Remarks ------0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0.00 to 5.00 0.00 to 5.00 0.00 to 5.00 0.00 to 5.00 -60 to +60 0.00 to 5.00 0 to 256,000 0 to 256,000 0 to 500 -60 to +60 0.00 to 5.00 -60 to +60 0.00 to 5.00 0 to 1,000 0 and 50 0 to 5 0 and 50 0 to 5 0 to +120 -----

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

4) Measuring steering pump outlet pressure using [Pm Clinic] a Select Pm Clinic on the SERVICE MENU SELECT screen.

Pm Clinic item Page 1/4 1/4 1/4 1/4 2/4 2/4 2/4 2/4 2/4 2/4 3/4 3/4 3/4 3/4 3/4 3/4 4/4 4/4 4/4 4/4 4/4 4/4 Item name Engine speed Engine oil pressure Engine oil temperature Engine coolant temperature Engine speed Blowby pressure Boost pressure Exhaust gas temperature Ambient temperature Common rail pressure Torque converter oil temperature Torque converter inlet pressure Torque converter outlet pressure Transmission main pressure Transmission lubricating oil pressure Modulation clutch pressure Hydraulic oil temperature PPC pressure Hydraulic oil pressure S/T pump pressure F brake oil pressure R brake oil pressure Sampling time 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S 2S Unit rpm kPa degC degC rpm kPa kPa degC degC MPa Detected components Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller KOMTRAX Plus controller Engine controller

degC Main moniter MPa MPa MPa MPa MPa C MPa MPa MPa MPa MPa KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller Transmission controller Main moniter KOMTRAX Plus controller Work equipment controller KOMTRAX Plus controller KOMTRAX Plus controller KOMTRAX Plus controller

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Before performing troubleshooting of steering oil pressure system (how to use the multi monitor)

Work equipment controller Displayed page 1/9 1/9 1/9 2/9 2/9 2/9 2/9 3/9 3/9 3/9 3/9 4/9 4/9 4/9 4/9 5/9 5/9 5/9 5/9 5/9 6/9 6/9 6/9 6/9 6/9 7/9 7/9 7/9 7/9 7/9 7/9 8/9, 9/9 Software No. Software application version Software application data version Boom (lift arm) Raise EPC Current 1 Boom (lift arm) Raise EPC Current 2 Boom (lift arm) Lower EPC Current 1 Boom (lift arm) Lower EPC Current 2 Bucket Tilt EPC Current 1 Bucket Tilt EPC Current 2 Bucket Dump EPC Current 1 Bucket Dump EPC Current 2 Lever potentiometer voltage boom (lift arm) 1 Lever potentiometer voltage boom (lift arm) 2 Lever potentiometer voltage bucket 1 Lever potentiometer voltage bucket 2 Boom (lift arm) angle Boom (lift arm) angle Boom (lift arm) lever operation frequency Bucket lever operation frequency Pump delivery AJSS lever operation angle AJSS lever potentiometer voltage Boom (lift arm) angle AJSS frame potentiometer voltage AJSS EPC Current Loader pump pressure Loader pump pressure Boom (lift arm) bottom pressure Boom (lift arm) bottom pressure AJSS S/T deviation angle Digging-in-progress flag Input/Output signal Signal name Unit ------1 mA 1 mA 1 mA 1 mA 1 mA 1 mA 1 mA 1 mA 0.01 V 0.01 V 0.01 V 0.01 V 0.1 deg 0.01 V ----1 cc 0.1 deg 0.01 V 0.1 deg 0.01 V 1 mA 0.01 MPa 0.001 V 0.01 MPa 0.001 V 0.1 deg 1: ON (digging) 0: OFF 1: ON 0: OFF(OPEN) Remarks ------0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0 to 1,000 0.00 to 5.00 0.00 to 5.00 0.00 to 5.00 0.00 to 5.00 -60 to +60 0.00 to 5.00 0 to 256,000 0 to 256,000 0 to 500 -60 to +60 0.00 to 5.00 -60 to +60 0.00 to 5.00 0 to 1,000 0 and 50 0 to 5 0 and 50 0 to 5 0 to +120 -----

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Troubleshooting of hydraulic and mechanical system (H-mode) Checking steering related standard values

Checking steering related standard values

(Lock-to-lock steering time is too long, shock is large, steering effort abnormal) (1) Standard value
Machine model Category Item
q q

40-608

WA1200-6 Unit Standard value for new machine Repair limit

Testing condition

Play
q

Steering

Operating effort Operating angle

q q q q q

Engine stopped Measure on lever knob (at 149 mm from lever pivot point) mm Hold the rotation of the steering rotary valve. Flat, level, straight, dry, and paved N {kg} road Engine speed: At full speed degree Left lock to right lock Engine started Hydraulic oil temperature: 45 to 55 C Left lock to right lock

Steering lever

Max. 8 13.7 5.0 {1.4 0.5} 80 8 Max. 6.5 5.7 0.5

Max. 16 23.5 {2.4} Max. 90 Max. 7.5 5.7 0.5 4.9 0.4 Max. 6.5 31.36 (+0.98/-1.27) {320 (+10/-13)} 3.72 (+0.39/-0.19) {38 (+4/-2)}

Operating time

Low idle High idle

sec.

4.9 0.4 Max. 5.6

Steering

Steering relief pressure Orbit-roll output pressure

q q

31.36 (+0.98/-0.29) MPa Hydraulic oil temperature: 45 to {320 (+10/-3)} 55 C {kg/cm2 3.72 (+0.19/0) Engine speed: At full speed } {38 (+2/0)}

(2) If abnormal shocks are reported, confirm the conditions under which they occur.
Engine speed Lo F1 While travelF2 ling F3 During work No load Loaded At beginning of steering At end of steering Mid Hi

Response

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure system, general

Steering oil pressure system, general

a The general structure of this section is shown below.
Item Steering oil pressure group Steering general function diagram 1. Walk-around check 1) Function diagram 2) Troubleshooting flow 3) Walk-around machine check 4) Visual check around hydraulic tank 1] Checking for looseness of hydraulic tank cap (oil stains around oil filler port) 2] Checking for missing gasket of hydraulic tank cap 3] Checking if transducer (if equipped) valve is closed 4] Checking and replacement of breather element 5] Cleaning and replacement of hydraulic oil central breather air element (if equipped) 6] Breather layout drawing 5) Checking oil level 1] Checking oil level in engine oil pan, and adding oil 2] Checking oil level in transmission, and adding oil 3] Checking oil level in hydraulic tank, and adding oil 6) Measuring steering lock-to-lock operating time 2. Checking standard values by using KOMTRAX Plus (checking steering pilot circuit group and linkages) 1) Function diagram 2) Troubleshooting flow 3) Checking engine speed RPM set ON/OFF switch RPM set idle-up/down selector switch 4) Adjusting steering stopper bolt 5) Adjusting steering follow-up linkage 6) Checking steering EPC valve 7) Testing and adjusting steering surge cut valve oil pressure 8) Testing and adjusting steering main relief valve oil pressure 3. Checking steering pump (sub), switch pump (sub), steering valve (left) group 1) Function diagram 2) Troubleshooting flow 4. Checking steering pump (main), switch pump (main), steering valve (right) group 1) Function diagram 2) Troubleshooting flow 3) AJSS neutral interlock function 4) Layout of components 5) Checking right and left steering valves individually 6) Steering pump (main) CO valve characteristics 7) Pump checking procedure Reference document page 40-610 40-610 40-612 40-612 40-613 40-614 40-614 40-614 40-614 40-615 40-615 40-616 40-618 40-620 40-620 40-620 40-621 40-621 40-622 40-622 40-623 40-624 40-626 40-627 40-628 40-628 40-632 40-634 40-636 40-638 40-638 40-639 40-640 40-640 40-641 40-642 40-643 40-646 40-648 40-649

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Troubleshooting of hydraulic and mechanical system (H-mode) 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.

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-612 1. Walk-around check 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-612

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

2) Troubleshooting flow 40-613 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.

Refer to page A: 40-614 B: 40-614, 615 C: 40-620, 621 D: 40-621 E: 40-622

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-614 3) Walk-around machine check Check for oil leaks from hydraulic piping around and inside the machine.

4) Visual check around hydraulic tank 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

a Opening and closing directions of valve

40-616

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

4] Checking and replacement of breather element Check the appearance of breather and filter element.

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40-617

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

6] Breather layout drawing

40-618

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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40-619

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

5) Checking oil level 1] Checking oil level in engine oil pan, and adding oil k Immediately after the engine is stopped, its parts and oil is still be very hot and you may be scalded. Wait until their temperature drops before starting the work. a When checking with the engine stopped, wait for at least 15 minutes after stopping the engine, and check the oil level. a When checking, park the machine on a level ground. 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).

40-620 2] Checking oil level in transmission, and adding oil k Immediately after the engine is stopped, its parts and oil are still very hot. Therefore, wait until their temperature drops before starting the work. a Before starting the engine, make sure that the oil level is within upper A or between upper A and lower B of sight gauge (G). 1. Run the engine at low idle. 2. Remove the cap of oil filler port (F).

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

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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. 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 adding oil k Immediately after the engine is stopped, its 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 slowly to release the internal pressure, then remove 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 Measurement condition q Engine started q Hydraulic oil temperature: 45 to 55 C q Left lock to right lock Operating time
Item Low idle High idle Standard value for new machine 5.7 0.5 4.9 0.4 Repair limit 5.7 0.5 4.9 0.4

40-621

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.

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40-621

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

2. Checking standard values by using KOMTRAX Plus (checking steering pilot circuit group and link40-62 ages) 1) Function diagram 40-62 a Check portions shown with hatched lines in the drawing.

40-622

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

2) Troubleshooting flow 40-623 Contents of work (1) Measure the engine speed and PPC relief oil pressure by using KOMTRAX Plus.

Refer to page A: 40-619 B: 40-622, 623 C: 40-638 D: 40-637 E: 40-643

F: 40-629 G: 40-632 H: 40-632, 633 I: 40-638

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40-623

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-624 3) Checking engine speed 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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 625 675 625 675 1,850 1,950 1,800 2,000 1,800 2,000 1,650 2,000 12.5 0.5 5.0 0.5 2.3 0.3 3.7 0.3 1,850 1,950 1,750 1,950 1,750 1,950 1,600 1 ,950 13.7 0.5 5.0 0.5 2.5 0.3 3.7 0.3

Engine speed Low idle (rpm) High idle Hydraulic relief At torque converter stall Full stall Work equipment speed Boom (lift arm) RAISE time (at high idle) Boom (lift arm) LOWER time (sec) Ground tilting time No load Dumping time

(2) Stall speed

Engine MODE: fixed to AUTO or P Engine Engine MODE: fixed MODE: fixed to AUTO or to E P At torque converter stall Engine speed
q

Engine MODE: fixed to E Engine MODE: fixed to AUTO or P Engine MODE: fixed to E

Hydraulic stall At torque converter stall and Hydraulic stall

q q

Coolant: 1,800 2,000 1,750 1,950 1,700 2,000 1,650 2,000 Within operating range Torque converter oil temperature: 60 rpm 1,800 2,000 1,750 1,950 1,700 2,000 1,650 2,000 80 C Hydraulic oil temperature: 45 55 C Gear shift lever: F4 1,650 2,000 1,600 1,950 1,550 2,000 1,500 2,000 or R4

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40-625

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

RPM set ON/OFF switch (1) 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.

40-626

40-626 Supplementary explanation 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.

40-626

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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 selector 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): This is used when setting the engine speed or increasing the set speed. q Using the accelerator pedal Depress the accelerator pedal and press portion (c) of switch at the desired engine speed. The speed is stored and set. q Using the RPM set idle-up/down switch When portion (c) of switch is pressed and held down for longer than 0.5 sec. the engine speed increases. Release the switch at the desired speed. The new speed is stored and set. Position (d): This is used when decreasing the set the engine speed, or recover the RPM set switch after it has 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.

40-627 Supplementary explanation q Setting engine speed with the RPM set switch is advantageous because excessive lowering in engine speed can be avoided during work using the accelerator pedal. The engine response will be better and the cycle time of work can be reduced. q Since the travel speed can be maintained constant while travelling for load-and-carry operation, the operator's fatigue can be reduced. q If resetting the engine speed to a desired speed without using portion (d) of the RPM set idle-up/down selector switch, depress the right brake pedal to cancel the set speed, and then depress the accelerator pedal to increase the engine speed. Depress setting side (c) of the switch at the desired speed. The new speed is stored and set.

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40-627

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-628 4) Adjusting steering stopper bolt Be sure to follow "Safety precautions to follow before starting work". 1. With the engine running at low idle, steer to the right or left. If clearance (a) between frame end stopper (2) of front frame (1) and rear frame (3) is out of the specified range, adjust it in the following procedure. a Clearance (a): 37 to 40 mm

5) Adjusting steering follow-up linkage 40-628 k Be sure to follow "Safety precautions to follow before starting work". 40-628 Adjusting 1. Move the frame lock bar to the "LOCK" position and set the machine in the straight travel position.

1) Loosen lock nut (4) and turn steering angle adjustment bolt (5) to meet clearance (a) to the standard value. k Withe engine running at low idle, slowly 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 oblong 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}

2. Adjust length "L" of steering follow up linkage (1) to the specified length. a Specified length L: 342 mm

a Notes for connectors The connectors for the frame angle and lever angle potentiometers (56B-06-11630) are Deutsche connectors (08192-13810).

40-628

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

3. In this condition, measure the voltage at frame angle potentiometer (2) and lever angle potentiometer (4). a Voltage when potentiometer is in neutral position: 2.5 0.3 V 4. If the voltage is not 2.5 0.3 V, loosen mounting 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".

Adjusting installed position of potentiometer 40-629 (work in pair) a The installed position of the potentiometer can be adjusted while watching the multi monitor display screen. 1. Display the "SERVICE MENU SELECT display screen" of the service mode. Use the [F3] or [F4] switch to select the function and the [F6] switch 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 "Articulating angle" and adjust the installed position of the potentiometer to meet the standard range.

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40-629

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

Offset angle automatic correction procedure for 40-630 lever angle and frame angle potentiometers 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 procedure 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

3. Operate the machine body as instructed on the screen and press [F6]. This sends a set signal to the work equipment controller. A message appears according to the command (setting completed or setting failed) from the work equipment controller. When setting is completed: "Setting Completed" When setting is not completed: "Setting failed" Until receiving a command: "Setting" Pressing [F6] sends a set signal to the work equipment controller.

After sending the signal, the adjustment current value is updated according to a signal from the work equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. If the [F1] switch is pressed, the screen returns to the adjustment menu (2) AJSS screen.

4. Pressing [F6] displays the adjustment current value according to the information from the work equipment controller. " ---" is displayed for the value until the information is received first after the screen transition. Pressing [F3] sends an UP signal to the work equipment controller. After sending the signal, the adjustment current value is updated according to a signal from the work equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. Pressing [F4] sends a DOWN signal to the work equipment controller.

5. Pressing [F6] displays the table pattern number according to the information from the work equipment controller. "---" is displayed for the number until the information is received first after the screen transition. Pressing [F6] switch sends an AJSS oil pressure command table pattern change signal to the work equipment controller. After sending the signal, the pattern number is updated according to a signal from the work equipment controller. A change of the numeric value is displayed according to the work equipment controller. The multi monitor is not concerned with changes in the numeric value through button operations. If the [F1] switch is pressed, the screen returns to the adjustment menu (2) AJSS screen.

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40-631

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

6) Checking steering EPC valve

40-632

Testing 40-632 k Be sure to follow "Safety precautions to follow before starting work". k Lock the front frame and rear frame by using frame lock bars and chock the wheels to prevent 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 pressure 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 abnormal end, but the multi monitor (KOMTRAX Plus) performs processing after moving. If the [F5] switch is pressed after the message is confirmed, the adjustment menu (2) AJSS screen appears. When the communication error with the controller continues for 0.5 second or more during the adjustment, the screen returns to SERVICE MENU SELECT screen without moving to the abnormal end screen.

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 lever steered) 0.49 to 0.64 MPa {4.8 to 6.3 kg/cm2})

40-632

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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40-633

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

7) Testing and adjusting steering surge cut valve oil pressure a Testing tools
Symbol Part No. Part name

40-634

Oil pressure gauge kit (analog) 799-101-5002 (Pressure gauge: 60 MPa 1 {600 kg/cm2}) C 790-261-1204 Oil pressure gauge kit (digital) 2 799-101-5160 q Nipple 5 799-203-2440 Nipple

Testing condition q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Lock the front frame and rear frame by using frame lock bars. k Loosen the oil filler cap of the hydraulic tank to release the pressure inside the hydraulic tank, then operate the steering lever two or three times to release the remaining pressure in the piping. a The procedure is common for both sides except for the location of the hydraulic pressure measuring points. a An oil pressure sensor (2) is installed on the left steering valve. 40-634 Testing 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 pressures are merged at the outlet side of the steering valve, right and left pressures cannot be measured separately at the outlet side. 1) When measuring the left steering valve oil pressure, remove steering oil pressure sensor (2) from tube (1) between the steering pump and steering valve, install nipples C5 and C2, and then install oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2) When measuring the right steering valve oil pressure, remove plug (4) from tube (3) between the steering pump and steering valve, install nipples C5 and C2, and then connect oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2. Loosen lock nut (6) on steering main relief valve (5), and screw in the adjustment screw (7) half a turn. a Ensure that only surge cut valve (8) is allowed to operate. q Steering main relief valve set pressure: 31.0 to 31.9 MPa {316 to 325 kg/cm2} q Surge cut valve set pressure: 33.3 to 34.3 MPa {340 to 350 kg/cm2}

40-634

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-635 Adjusting a If the surge cut valve (8) set pressure is not correct, 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 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.

Stop the engine before adjusting the surge cut valve. 1. Loosen lock nut (9) for the surge cut valve and turn adjustment screw (10) to adjust the pressure. a Turn the adjustment screw clockwise to increase the set pressure and turn it counterclockwise to decrease the pressure. a Pressure adjustment per one turn of adjustment 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, adjust the main relief valve. a After testing, bleed air from the circuit and check the oil level.

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40-635

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

8) Testing and adjusting steering main relief valve oil pressure a Testing tools
Symbol Part No. Part name

40-636

Oil pressure gauge kit (analog) 799-101-5002 (Pressure gauge: 60 MPa 1 {600 kg/cm2}) C 790-261-1204 Oil pressure gauge kit (digital) 2 799-101-5160 q Nipple 5 799-203-2440 Nipple

Testing condition q Hydraulic oil temperature: 45 to 55 C k Be sure to follow "Safety precautions to follow before starting work". k Park the machine on a level ground, apply the parking brake, lower the bucket to the ground, and reserve a safe area. k Chock the wheels to prevent the machine from moving. k Lock the front frame and rear frame by using frame lock bars. k Loosen the oil filler cap of the hydraulic tank to release the pressure inside the hydraulic tank, then operate the steering lever two or three times to release the remaining pressure in the piping. a The procedure is common for both sides except for the location of the hydraulic pressure measuring points. 40-636 Testing 1. Steering main relief valve oil pressure must be measured at the pump inlet side circuit of the steering valve. a Since the right and left steering valve pressures are merged at the outlet side of the steering valve, right and left pressures cannot be measured separately at the outlet side. 1) When measuring the left steering valve oil pressure, remove steering oil pressure sensor (2) from tube (1) between the steering pump and steering valve, install nipples C5 and C2, and then install oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2) When measuring the right steering valve oil pressure, remove plug (4) from tube (3) between the steering pump and steering valve, install nipples C5 and C2, and then install oil pressure gauge C1 (60 MPa {600 kg/cm2}) to nipple C2.

2. Start the engine and run at high idle (engine speed: 2,050 rpm). Measure the oil pressure when the steering lever is moved to the right or left and the main relief valve is actuated. q Main relief valve set pressure: 31.0 to 31.9 MPa {316 to 325 kg/cm2}

40-636

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

Adjusting 40-637 a If the set pressure of main relief valve (5) is not correct, adjust the main relief valve according to the following procedure.

Stop the engine before adjusting the main relief valve.

1. Loosen lock nut (6) of the main relief valve and turn adjustment screw (7) to adjust the pressure. a Turn the adjustment screw clockwise to increase the set pressure and turn it counterclockwise to decrease the pressure. a Pressure adjustment per one turn of adjustment 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 accurately.

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40-637

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

3. Checking steering pump (sub), switch pump (sub), steering valve (left) group 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-638 40-638

40-638

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

2) Troubleshooting flow 40-639 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.

Refer to page A: 40-619 B: 40-645 C: 40-637 D: 40-621, 622 E: 40-644

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40-639

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

4. Checking steering pump (main), switch pump (main), steering valve (right) group 1) Function diagram a Check portions shown with hatched lines in the drawing.

40-640 40-640

40-640

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

2) Troubleshooting flow 40-641 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.

Refer to page A: 40-634, 635 B: 40-636 C: 40-643 D: 40-637 E: 40-644

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40-641

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-642 3) AJSS neutral interlock function 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 position 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

4) Layout of components

40-643

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40-643

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-644

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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40-645

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

5) Checking right and left steering valves individually

40-646

40-646

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

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40-647

Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

40-648 6) Steering pump (main) CO valve characteristics The pump detects the self pressure. If the pump delivery pressure increases, it decreases the pump delivery.

40-648

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Troubleshooting of hydraulic and mechanical system (H-mode) Steering oil pressure group

7) Pump checking procedure 40-649 (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

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40-649

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure system, general

Brake oil pressure system, general

a The general structure of this section is shown below.
Item Brake oil pressure group Brake system circuit diagram Brake function system diagram Layout of components 1. Walk-around check 1) Function diagram 2) Troubleshooting flow 3) Walk-around machine check 4) Visual check around brake oil tank 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 4] Checking and replacement of breather element 5] Breather layout drawing 5) Checking oil level 6) Checking strainer 2. Checking for performance deterioration by using KOMTRAX Plus (hydraulics section) 1) Function diagram 2) Troubleshooting flow 3) Warning display on multi monitor 1] Front brake oil pressure too low (during operation) 2] Rear brake oil pressure too low (during operation) 3] Brake oil level too low (during operation) 4] Front and rear brake oil pressure too low (at engine start) 5] Brake oil level too low (before engine start) 3. Checking for internal leaks in components such as valves, accumulators (oil leaks, etc.) 1) Function diagram 2) Troubleshooting flow 3) Brake related components layout drawing 4) Checking of accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 5) Explanation of brake pump outlet pressure 6) Measuring accumulator charge cut-in and cut-out pressures 7) Checking for brake accumulator oil pressure leakage Reference document page 40-651 40-651 40-654 40-655 40-665 40-665 40-668 40-669 40-669 40-669 40-669 40-669 40-671 40-672 40-674 40-674 40-675 40-676 40-678 40-679 40-679 40-679 40-679 40-680 40-680 40-681 40-681 40-684 40-686 40-688 40-693 40-697 40-699

40-650

40-650

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Brake oil pressure group

Brake system circuit diagram

40-651
40-651

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40-651

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-652

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Brake function system diagram 40-653 a Relation between the hydraulic components and electrical components that consist the brake system are shown.

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40-653

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-654

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Layout of components 40-65 a For part number and part names, see the parts book. Transmission Accumulator

Accumulator circuit

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40-655

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Accumulator charge valve

Front brake circuit

Accumulator (bracket)

Rear brake circuit

40-656

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Floor circuit 1/3

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40-657

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Floor circuit 2/3

Floor circuit 3/3

40-658

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Pump circuit

Suction circuit 1/2

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40-659

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Suction circuit 2/2

Parking circuit

40-660

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Brake oil tank and related

Brake piping drain circuit

WA1200-6

40-661

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Slack adjuster 42C-43-17202

Brake valve single 421-43-27100

40-662

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Brake valve tandem 421-43-17101

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40-663

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-664

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

1. Walk-around check 40-6 5 1) Function diagram 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.

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40-665

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Function diagram

40-6 6

40-666

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

WA1200-6

40-667

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

2) Troubleshooting flow 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

40-6 8

Refer to page A: 40-669 B: 40-669, 670 C: 40-674 D: 40-674 E: 40-679

F: 40-669 G: 40-671 H: 40-669

40-668

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

3) Walk-around machine check 40-6 9 Check for oil leaks from hydraulic piping around and inside the machine.

4) Visual check around brake oil tank 1] Checking for looseness of brake oil tank cap (oil stains around oil filler port)

40-6 9 2] Checking if element is a genuine part

3] Checking if transducer (if equipped) valve is closed

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

a Opening and closing directions of valve

40-670

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

4] Checking and replacement of breather element Check the appearance of breather and filter element.

WA1200-6

40-671

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

5] Breather layout drawing

40-672

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

WA1200-6

40-673

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-674 5) Checking oil level Checking brake oil level in tank and refilling k When refilling the brake oil tank, be sure to use the recommended genuine oil. 1. Check gauge (1) for brake cooling and gauge (2) for brake on the side of the brake oil tanks, 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 6) Checking strainer a Check the charge pump outlet side strainer, and replace the following items if abnormal metallic powder is found. q Brake pump q Brake element q Brake oil

40-674

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

2. Checking for performance deterioration by using KOMTRAX Plus (hydraulics section) 40-675 a For the function diagram, see the next page. q Check for performance deterioration of brake charge pump and accumulator charge valve by using KOMTRAX Plus(Locations marked with a) a For the contents of the work, see the troubleshooting flow.

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40-675

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

1) Function diagram

40-676

40-676

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

WA1200-6

40-677

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-678 2) Troubleshooting flow 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 B: 40-521, 522 C: 40-697

D: 40-698 E: 40-679

40-678

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

3) Warning display on multi monitor 1] Front brake oil pressure too low (during operation) This warning display warns about abnormality in the front brake oil pressure. q If the brake oil pressure lowers 14.72 MPa {150 kg/cm2} or less during operation: The title and message appears on the multi monitor as a display of abnormality. In this case, the title screen turns red, the centralized warning lamp (CAUTION) on the main monitor blinks, and the alarm buzzer sounds. If these alarms are given, stop the work immediately and check the brake oil pressure system.

40-679 3] Brake oil level too low (during operation) This warning display warns about abnormality in the brake oil level during operation. When the brake oil level warning is not displayed on the multi monitor, the system is normal. If the oil level in brake circuits or brake cooler circuits is too low, the title and message appears on the multi monitor as a display of abnormality. In this case, the title screen turns red, the centralized warning lamp (CAUTION) on the main monitor blinks, and the alarm buzzer sounds. If this happens, move the machine immediately to a safe place, stop the 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 operation) This warning display warns about abnormality in the rear brake oil pressure.

4] Front and rear brake oil pressure too low (at engine start) This warning display warns about abnormality in the front brake oil pressure and rear brake oil pressure. Front and rear brake accumulated oil pressure display

If the brake oil pressure is 14.72 MPa {150 kg/cm2} or less and in process of accumulating, the title and message appears on the multi monitor as a display of abnormality. In this case, the title screen turns red, and the centralized warning lamp (CAUTION) on the main monitor 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 abnormality display on the screen goes out. 40-679

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

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 circuits 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 display of abnormality. In this case, the title screen turns yellow, and the centralized check lamp (CHECK) on the main monitor 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

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

3. Checking for internal leaks in components such as valves, accumulators (oil leaks, etc.) 40-681 1) Function diagram 40-681 a For the function diagram, see the next page. 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 components) a For the contents of the work, see the troubleshooting flow.

WA1200-6

40-681

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Refer to page A: 40-686

40-682

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Refer to page A: 40-657 B: 40-657

WA1200-6

40-683

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-684 2) Troubleshooting flow 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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Refer to page A: 40-685, 686 B: 40-686 C: 40-686 D: 40-693-698 E: 40-694

F: 40-689 G: 40-693-698 H: 40-693 I: 40-693-698 J: 40-693

WA1200-6

40-685

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

3) Brake related components layout drawing

40-686

40-686

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Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

WA1200-6

40-687

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

4) Checking of accumulator nitrogen gas pressure and procedure for charging accumulator 40-68 with nitrogen gas a Testing tools
Symbol Part No. 792-610-1701 792-610-1700 07000-11009 1 792-610-1702 792-610-1700 07000-11009 792-610-2310 R 792-610-1310 792-610-1320 792-610-1330 2 792-610-1350 792-610-1360
k k

Part name Gas charge tool kit q Gas charge tool q O-ring Gas charge tool kit q Gas charge tool q O-ring q Extension Nipple (For Russia) Nipple (For USA) Nipple (For USA) Nipple (For Germany) Nipple (For UK)

Applicable standard For old type ACC

For old and new type ACC

GOST CGA No.351 ASA B-571-1965 DIN 477-1963 NEN3268-1966 SIS-SMS 2235/2238 BS 341 Part1-1962

Precautions when connecting the gas charge 40-68 tool R1 1. Sealant has been applied to the threaded portion of the adapter (5) for the gas charge tool R1. Never attempt to remove it unless absolutely necessary. Otherwise, the gas may leak out. 2. On some gas valves (4), the length of the threads (B) may be not long enough for the depth (A) from the end face of the adapter (5) to the packing (6) of the gas charge tool R1, preventing the gas valve (4) from seating completely. In such a case, nitrogen gas may leak out through the threads of the gas valve (4). 3. When connecting the gas charge tool R1 to the gas valve (4) but the extension (P/N: 792-610-2310) supplied with the tool is not available, install O-ring (7) (P/N: 07000-11009) supplied with the tool to gas valve (4). Connect the gas charge tool R1. Then, check to ensure that there is no leakage.

q q q q q

q q

Be sure to follow "Safety precautions to follow before starting work". 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. When handling nitrogen gas in a room or another place which is not ventilated well, ventilate the work place forcibly and observe the Oxygen Deficiency Prevention Rules of the Labor Safety and Sanitation Law. The accumulator is charged with high-pressure 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. Do not bring fire near the accumulator or put the accumulator in fire. Do not drill, weld or gas-cut the accumulator. Do not give impacts to the accumulator by hitting or rolling. When discarding accumulator, discharge it of the nitrogen gas. Before disassembly or removal, relieve the accumulator charge down to the atmospheric pressure. Only use nitrogen gas to fill the accumulator. Do not use oxygen or other explosive gas. When handling the accumulator, strictly observe the precautions given in this manual.

4. If extension (8) (P/N: 792-610-2310) supplied with the tool is available, install extension (8) to gas valve (4) and then connect gas charge tool R1. a The O-ring supplied with the tool will not be used.

40-688

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Testing nitrogen gas pressure in accumulator 40-689 a The measuring is also possible on the accumulator alone. a Nitrogen gas cylinder (c) must be connected even when you measure only the gas pressure. 1. Stop the engine and depress the brake pedal repeatedly to lower the oil pressure in the brake circuit to zero. 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 accumulator (1). (Old type accumulator)

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) 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

40-689

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

5. Slowly turn clockwise handle (a) of gas charge tool R1 and read the gauge. a Since the indicated value varies with the ambient 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 temperature C 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Gas pressure MPa 4.34 4.35 4.37 4.38 4.40 4.41 4.43 4.44 4.46 4.47 4.49 4.50 4.52 4.53 4.55 4.56 4.58 4.59 4.61 4.62 4.64 4.65 4.67 4.68 4.70 4.71 4.73 4.74 4.76 4.77 4.79 kg/cm2 44.2 44.4 44.5 44.7 44.8 45.0 45.2 45.3 45.5 45.6 45.8 45.9 46.1 46.2 46.4 46.5 46.7 46.8 47.0 47.2 47.3 47.5 47.6 47.8 47.9 48.1 48.2 48.4 48.5 48.7 48.8 Remarks

Procedure for charging accumulator with nitro40-690 gen gas a The accumulator can also be charged in a similar 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. 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 accumulator (1). (Old type accumulator)

Standard gas

3. Remove plug (9) from accumulator (1). (New type accumulator)

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 accumulator 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 counterclockwise. 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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

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) on accumulator (1). 5) Connect gas charge tool R1 to nitrogen gas cylinder (c). a Avoid applying bending load to the gas valve (4), which may otherwise break. a There are two types of threads of nitrogen gas cylinders; W22-14 threads (mail screw, type A) and W23-14 threads (female screw, type B). When using a gas cylinder of W23-14 threads (female screw, type B), connect the hose by using the adapter. (The adapter is supplied with the gas charge tool R1.) [Japan domestic] a Use nipple R2 to connect the hose depending on the specification of the nitrogen gas cylinder. [Overseas]

5. Slightly open the valve on the nitrogen gas cylinder (c) to discharge nitrogen gas at a pressure of approx. 0.19 to 0.29 MPa {2 to 3 kg/cm2}. 6. After nitrogen gas starts flowing out of handle (b), turn handle (b) to the clockwise to close. 7. Turn handle (a) slowly clockwise to open valve (4) of accumulator (1) gradually. a If handle (a) is turned too much, the valve core of the accumulator will be damaged and gas will leak. Accordingly, operate handle (a) carefully. 8. Open the valve of nitrogen gas cylinder (c) further to charge the accumulator with nitrogen gas. 9. During the work, close the valve of nitrogen gas cylinder (c) and check the nitrogen gas pressure in the accumulator. a Since the indicated value varies with the ambient 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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

Quick reference table for gas pressure in the accumulator

Ambient temperature C 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Gas pressure MPa 4.34 4.35 4.37 4.38 4.40 4.41 4.43 4.44 4.46 4.47 4.49 4.50 4.52 4.53 4.55 4.56 4.58 4.59 4.61 4.62 4.64 4.65 4.67 4.68 4.70 4.71 4.73 4.74 4.76 4.77 4.79 kg/cm2 44.2 44.4 44.5 44.7 44.8 45.0 45.2 45.3 45.5 45.6 45.8 45.9 46.1 46.2 46.4 46.5 46.7 46.8 47.0 47.2 47.3 47.5 47.6 47.8 47.9 48.1 48.2 48.4 48.5 48.7 48.8 Remarks

Standard gas

11. Remove gas charge tool R1 from gas valve (4) of accumulator (1) according to the following procedure. 1) Turn handle (a) counterclockwise to close the valve of the accumulator. 2) Turn handle (b) counterclockwise to open and discharge nitrogen gas remaining in gas charge tool R1 and hoses. 3) Remove gas charge tool R1 from gas valve (4) on the accumulator. 4) Remove extension (8) from gas valve (4). Alternatively, remove O-ring (7) from gas valve (4). 12. Apply soap water to gas valve (4) of the accumulator to ensure that nitrogen gas is not leaking. 13. Install plug (9) to accumulator (1). 3 Plug: 73.5 to 98.0 Nm {7.5 to 10.0 kgm}

t: Gas temperature when charging ( C) Reference: t may be assumed to be ambient temperature. 10. After the accumulator is charged to the standard pressure, close the valve of nitrogen gas cylinder (c). a If the accumulator is charged too much, turn handle (b) counterclockwise slowly with the valve of nitrogen gas cylinder (c) closed to release the nitrogen gas gradually to adjust.

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 stopping the engine. (If more than 5 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" position. 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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-694

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

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 comparing 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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

40-696

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

6) Measuring accumulator charge cut-in and 40-697 cut-out pressures k Be sure to follow "Safety precautions to follow before starting work". 40-697 Measurement Brake oil temperature: 45 to 55 C k Stop the engine, then depress the brake pedal at least 100 times to release the pressure inside the accumulator circuit. 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.
q

4. Measure the accumulator charge cut-out pressure. Measure the oil pressure when the rising oil pressure alters to drop. Cut-out pressure: 20.6 to 22.1 MPa {210 to 225 kg/cm2} 5. Measure the accumulator charge cut-in pressure. Start the engine and run at low idle. While observing the pressure drop, measure the minimum pressure when the oil pressure gradually alters from drop to rise (read the F brake pressure or R brake pressure on the multi monitor). Cut-in pressure: 17.6 to 18.2 MPa {180 to 186 kg/cm2} 6. If [F3] switch is pressed while reading the oil pressure, the value is held. a If the hold [F3] switch is pressed again, the 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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

(Reference) Change in accumulator charge pressure

40-698 Adjusting 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 provided. 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 increased. 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

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

7) Checking for brake accumulator oil pressure 40-69 leakage k Be sure to follow "Safety precautions to follow before starting work". k Lock the front frame and rear frame by using frame lock bars. 40-69 Testing Start and run the engine until the charge pressure 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 } 2 q Used machine: 20.6 MPa {210 kg/cm } a Check the charge pressure at "F brake oil pressure" or "R brake oil pressure" (page 4/4 of Pm Clinic menu screen) of the multi monitor.
q

4. Disconnect hose (3) between tube (2) of emergency parking brake valve (1) and the accumulator.

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). 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 release the remaining pressure.

WA1200-6

40-699

Troubleshooting of hydraulic and mechanical system (H-mode) Brake oil pressure group

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 pressure reaches the following value, and then stop the engine. The pressure must not drop below 14.7 MPa {150 kg/cm2} within 15 minutes. 2 q New machine: 17.6 MPa {180 kg/cm } 2 q Used machine: 20.6 MPa {210 kg/cm } 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 pressure. 8. Reconnect hose (3) to tube (2). 9. If the pressure dropped below 14.7 MPa {150 kg/cm2}, check for leaks from the emergency parking brake valve.

40-700

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) 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 diagram. Before performing troubleshooting, understand that information fully.
Failure Problem on machine Related information Information related to the detected failure or troubleshooting No. Cause Procedure, measuring location, criteria and remarks

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.)

WA1200-6

40-701

Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Torque converter oil temperature rises too high (overheats)

H-1 Torque converter oil temperature rises too high (overheats)

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)

40-702

Related infor(2) In what working condition does it occur? Travelling downhill or during digging? mation (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). No. Cause Procedure, measuring location, criteria and remarks a Engine speed can be checked with monitoring function. a E: Economy mode P: Power mode Engine speed Low idle High idle Torque converter stall Hydraulic stall (Lift arm RAISE relief) Hydraulic stall (Bucket TILT relief) Full stall (torque converter stall + hydraulic stall) E P E P E P E P Engine speed (rpm) 575 725 1,800 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,500 2,000 1,550 2,000 Oil pressure (MPa {kg/cm2})

1 Defective engine body

a Transmission main relief pressure can be checked with monitoring function. Check item Defective transmission main relief 2 valve
q

Transmission main 2.7 0.15 relief pres{28 1.5} q sure Torque conq verter Max. 1.22 inlet oil {max. 13} pressure a Torque converter outlet oil pressure can be checked with monitoring function. Oil pressure (MPa q Engine coolant temperature: With- Check item Defective torque converter regula{kg/cm2}) in operating range 3 tor valve Torque conq Torque converter oil temperature: verter 0.88 0.1 60 80 C outlet oil {9 1} q Engine speed: High idle pressure Engine coolant temperature: Within operating range Torque converter oil temperature: 60 80 C Engine speed: High idle

40-702

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Torque converter oil temperature rises too high (overheats)

No.

Cause

Procedure, measuring location, criteria and remarks 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 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 Engine at high idle q Torque converter stall Measure torque converter inlet and outlet pressures under above conditions
q

4 Defective operation

Check item Inlet pressure Outlet pressure Check item Difference between oil temperatures

Standard value (MPa {kg/cm2}) 0.3 0.5 {3 5} 0.15 0.25 {1.5 2.5} Standard value ( C) 11 to 13

Defective torque converter oil 5 cooler

Measure torque converter inlet and outlet temperatures under above conditions

a Measure fan speed for additional cooler

q

6 Defective additional oil cooler

Engine speed: High idle STD: 2,050 50 rpm 100 rpm lowered specification: 1,900 50 rpm Hydraulic oil temperature: 45 to 55 C Engine speed: High idle Hydraulic oil temperature: 45 to 55 C

Fan speed (rpm)

2,000 100

a Measure priority relief valve set pressure

q q

Set pressure ( MPa {kg/cm2}) 14.7 1.0 {150 10}

a Check the oil cooler for clogging and clean if clogged.

WA1200-6

40-703

Troubleshooting of hydraulic and mechanical system (H-mode) H-1 Torque converter oil temperature rises too high (overheats)

No.

Cause

Procedure, measuring location, criteria and remarks

a Transmission modulation oil pressure can be checked with monitoring function. q Engine coolant temperature: WithModulation clutch oil pressure in operating range (MPa {kg/cm2}) q Torque converter oil temperature: 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

Troubleshooting of hydraulic and mechanical system (H-mode) H-2 Turning or response of steering is poor

H-2 Turning or response of steering is poor

Failure Turning or response of steering is poor. Ask the operator and check the following points (1) Does the turning of machine become poor suddenly? Is any unusual noise heard at the time? And from where? (Breakage of related equipment)

40-705

Related infor(2) Were there any symptoms of dull steering response previously? mation (3) Is the tire inflation pressure correct? a Check before troubleshooting: Check whether the level and type of oil in the hydraulic tank is appropriate. No. Cause Procedure, measuring location, criteria and remarks a Engine speed can be checked with monitoring function. a E: Economy mode P: Power mode Engine speed Low idle High idle 1 Defective engine body Torque converter stall Hydraulic stall (Bucket TILT relief) Full stall (torque converter stall + hydraulic stall)
q

Engine speed (rpm) 575 725 1,800 2,000 E P E P E P 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,500 2,000 1,550 2,000

a Steering oil pressure can be checked with monitoring function. Lock the front and rear frames by using frame lock bars, and chock the wheels. Oil pressure (MPa Hydraulic oil temperature: 45 to Check item {kg/cm2}) 55 C Engine speed: Low idle Screw-in the main relief valve by a R.H. steering 33.3 34.3 half turn valve oil pressure {340 350} Measure the steering serge-cut oil pressure when the joystick lever is L.H. steering 33.3 34.3 moved to the right or left to relief. valve oil pressure {340 350} Oil pressure (MPa Check item {kg/cm2}) Hydraulic oil temperature: 45 to 55 C Engine speed: High idle 31.36(+0.98/-1.27) R.H. steering 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)}

Defective surge cut oil pressure valve

q q q

Defective 2 steering valve

Defective main relief valve

q q

Defective suction safety valve of steering valve

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 q If oil pressure in step 2 is lower than the standard value and the set pressure 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

Troubleshooting of hydraulic and mechanical system (H-mode) H-2 Turning or response of steering is poor

No. 4

Cause Defective demand valve of steering valve

Procedure, measuring location, criteria and remarks a If the steering jolts to the right or left at near the NEUTRAL position when the work equipment is operated, the demand valve may be defective. Check the movement of the spool directly. Oil pressure (MPa q Lock the front and rear frames by 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} 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 q

5 Defective steering EPC valve

Defective steering control lever (AJSS)

Engine at low idle Standard value Set the machine in the straight trav- for new machine el position, and slowly move the (mm) steering control lever to the right (left). At certain point, machine starts to turn. Then move the steerMax. 8 ing control lever to the left (right). At certain point, machine starts to turn to the other direction. Measure the stroke between those two points. Check item Length of the follow-up linkage rod Lever angle Engine stopped Set the machine in the straight trav- potentiometer voltage at NEUel position. TRAL Frame angle potentiometer voltage at NEUTRAL Engine at low idle Check item Steer to the right and left, and meaClearance sure the clearance between front between the front and rear frames when the steering frame and rear stops. frame

Repair limit (mm)

Max. 10

a Check the steering follow-up linkage Standard value 342 mm

Defective steering follow-up linkage

q q

2.5 0.3 V

2.5 0.3 V

a Measure the clearance between front frame end stopper and rear frame 8 Defective adjustment of steering stopper bolt
q q

Standard value 37 40 mm

a Check the rotary valve (Orbit-roll) Check item

q

Defective rotary valve 9 (Orbit-roll)

Engine stopped Measure the input torque when the Valve displacement output shaft is locked angle10 deg. Measure the input torque when the output shaft is free

Standard value (Nm {kgm}) 1.47 1.96 {0.15 0.20} 0.98 {0.10}

10 Defective steering cylinder

a If no failure is found by checks on causes 1 to 9 above, the steering cylinder may be defective. Check it directly.

40-706

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) H-2 Turning or response of steering is poor

No.

Cause

Procedure, measuring location, criteria and remarks 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. Steering time q Hydraulic oil temperature: 45 to Engine speed (sec.) 55 C q Measure the time required for Low idle Max. 5.7 steering right (left) end to left (right) High idle Max. 4.9 end.

11 The steering pump is defective

WA1200-6

40-707

Troubleshooting of hydraulic and mechanical system (H-mode) H-3 AJSS lever is hard to operate

H-3 AJSS lever is hard to operate

Failure AJSS lever is hard to operate Ask the operator and check the following points (1) Does the AJSS lever become suddenly hard to operate? Is any unusual noise heard at the time? And from where? (Breakage of related equipment)

40-708

Related infor(2) Were there any symptoms of stiff AJSS lever previously? (Wear of related equipment) mation (3) Is the tire inflation pressure correct? a Check before troubleshooting: Check whether the level and type of oil in the hydraulic tank is appropriate. No. Cause Procedure, measuring location, criteria and remarks a Measure the AJSS lever operating effort q Engine coolant temperature: Within operating range q Hydraulic oil temperature: Within operating range q Engine speed: Low idle
q

Check item NEUTRAL o Right end NEUTRAL o Left end

Operating effort (N {kg}) Max. 23.5 {max. 2.4} Max. 23.5 {max. 2.4}

a Measure the play of AJSS lever Check item Play (mm) Engine at low idle q Set the machine in the straight trav1 Defective AJSS Lever el position, and slowly move the steering control lever to the right (left). At certain point, machine Play of starts turning. Then move the Max. 10 AJSS lever steering control lever to the left (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. 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. Oil pressure (MPa Check item {kg/cm2}) q Hydraulic oil temperature: 45 to 55 C R.H. steering 33.3 34.3 Defective surge cut oil q Engine speed: Low idle valve oil pres{340 350} pressure 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 33.3 34.3 2 steering or left to relief. valve oil pres{340 350} valve sure Check item
q q q

Defective relief valve

Hydraulic oil temperature: 45 to 55 C Engine speed: High idle Measure the steering oil pressure when the joystick lever is moved to the right or left to relief.

Oil pressure (MPa {kg/cm2}) 31.0 31.9 {316 325} 31.0 31.9 {316 325}

R.H. steering valve oil pressure L.H. steering valve oil pressure

40-708

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) H-3 AJSS lever is hard to operate

No.

Cause
q

Procedure, measuring location, criteria and remarks Lock the front and rear frames by using frame lock bars, and chock the wheels. Engine at low idle Slowly move the steering control lever right and left at near the NEUTRAL position and then read the pressure when it is at the minimum. Check item AJSS lever in NEUTRAL Right turn Left turn Oil pressure (MPa {kg/cm2}) 0.47 0.62 {4.8 6.3} 0.88 1.08 {9 11} 0.88 1.08 {9 11} Standard value (Nm {kgm}) 1.47 1.96 {0.15 0.20}

3 Defective steering EPC valve

q q

a Check the rotary valve (Orbit-roll) Defective rotary valve (Orbit-roll)

q q q

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".

Check item Engine stopped Measure the input torque when the Valve displaceoutput shaft is locked ment Measure the input torque when the angle10 deg. output shaft is free

WA1200-6

40-709

Troubleshooting of hydraulic and mechanical system (H-mode) H-4 Steering shakes or jolts

H-4 Steering shakes or jolts

Failure Steering shakes or jolts Ask the operator and check the following points (1) Does the steering start to shake or jolt suddenly? Is any unusual noise heard at the time? And from where? (Breakage of related equipment)

40-710

Related infor(2) Were there any symptoms of steering shake or jolts previously? mation (3) Is the tire inflation pressure correct? a Check before troubleshooting: Check whether the level and type of oil in the hydraulic tank is appropriate. No. Cause Procedure, measuring location, criteria and remarks a Engine speed can be checked with monitoring function. a E: Economy mode P: Power mode Engine speed Low idle High idle 1 Defective engine body Torque converter stall Hydraulic stall (Bucket TILT relief) Full stall (torque converter stall + hydraulic stall) E P E P E P Engine speed (rpm) 575 725 1,800 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,500 2,000 1,550 2,000

Defective 2 steering valve

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. Oil pressure (MPa Check item {kg/cm2}) q Hydraulic oil temperature: 45 to 55 C R.H. steering 33.3 34.3 Defective surge cut oil q Engine speed: Low idle valve oil pressure {340 350} pressure q Screw-in the main relief valve by a half turn q Measure the oil pressure when the joystick lever is moved to the right L.H. steering 33.3 34.3 or left to relief. valve oil pressure {340 350} Oil pressure (MPa {kg/cm2}) 31.0 31.9 {316 325} 31.0 31.9 {316 325}

Check item
q

Defective main relief valve

q q

Hydraulic oil temperature: 45 to 55 C R.H. steering Engine speed: High idle valve oil pressure Measure the steering oil pressure when the joystick lever is moved to L.H. steering the right or left to relief. valve oil pressure

Defective suction safety valve of steering valve

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 q If oil pressure in step 2 is lower than the standard value and the set pressure 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

Troubleshooting of hydraulic and mechanical system (H-mode) H-4 Steering shakes or jolts

No. 4

Cause Defective demand valve of steering valve

Procedure, measuring location, criteria and remarks a If the steering jolts to the right or left at near the NEUTRAL position when the work equipment is operated, the demand valve may be defective. Check the movement of the spool directly. Oil pressure (MPa Check item q Lock the front and rear frames by {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 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 pressure when it is at the minimum. Left turn {9 11} a Measuring play of steering control lever
q q

5 Defective steering EPC valve

Defective steering control lever (AJSS)

Engine at low idle Standard value Set the machine in the straight trav- for new machine el position, and slowly move the (mm) steering control lever to the right (left). At certain point, machine starts turning. Then move steering control lever to the left (right). At Max. 8 certain point, machine starts turning to the other direction. Measure the stroke between these two points. Check item Length of the follow-up linkage rod Lever angle Engine stopped Set the machine in the straight trav- potentiometer voltage at NEUel position. TRAL Frame angle potentiometer voltage at NEUTRAL Engine at low idle Check item Steer to the right and left, and meaClearance sure the clearance between front between the front and rear frames when the steering frame and rear stops. frame

Repair limit (mm)

Max. 10

a Check the steering follow-up linkage Standard value 342 mm

Defective steering follow-up linkage

q q

2.5 0.3 V

2.5 0.3 V

a Measure the clearance between front frame end stopper and rear frame 8 Defective adjustment of steering stopper bolt
q q

Standard value 37 40 mm

a Check the rotary valve (Orbit-roll) Defective rotary valve (Orbit-roll) Standard value (Nm Check item Engine stopped {kgm}) q Measure the input torque when the Valve displace1.47 1.96 ment output shaft is locked {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 may be defective. Check it directly.
q

10 Defective steering cylinder

WA1200-6

40-711

Troubleshooting of hydraulic and mechanical system (H-mode) H-5 Wheel brake does not work at all or is weak

H-5 Wheel brake does not work at all or is weak

Failure Wheel brake does not work at all or is weak (failure code is issued) Ask the operator and check the following points (1) Does the brake become weak suddenly? (Is the failure code issued at the time?) Is any unusual noise heard at the time? And from where? (Breakage of related equipment) (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 appropriate. No. Cause
q

40-712

Procedure, measuring location, criteria and remarks Category Oil level Empty the brake accumulator and check the oil level (depress the Tank for brake right and left brake pedals altercooling nately until the pedal operating efBetween Hi and Low fort becomes small). on tank gauge Check with the engine running at Brake oil tank low idle

Defective brake oil level

a If a failure code is displayed on the monitor, perform troubleshooting for it by referring to the corresponding troubleshooting sheet.
q q

Failure code: B@C5ZK Failure code: b@C5ZK

Displayed during work Displayed before the engine is started

a Download the KOMTRAX Plus snap shot and check Engine at low idle Brake oil pressure Category Parking brake: OFF (MPa {kg/cm2}) q Directional selector switch "N" Caution issue14.7 Under the above conditions, depress dioCleared {150} the right and left brake pedals alternately. Measure the oil pressure when Emergency P 11.3 13.3 the oil pressure is decreased and caubrake {115 135} 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.) a If a failure code is displayed on the monitor, perform troubleshooting for it by referring to the corresponding troubleshooting sheet. q Failure code: 2G42ZG (During opFront brake oil pressure too low eration) q Failure code: 2G43ZG (During opRear 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 Category brake pedal at least 100 times to {kg/cm2}) release the pressure inside the 17.6 18.2 Cut-in accumulator circuit. {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)
q q

Defective oil pressure switches

Defective charge valve

40-712

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) H-5 Wheel brake does not work at all or is weak

No.

Cause

Procedure, measuring location, criteria and remarks 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 Clean, replace, or correach the standard value) (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 (2) Run the engine at low idle, and then stop when the brake oil pressure reaches 20.6 MPa {210 kg/cm2} (3) Keep the engine stopped for 15 minutes, then measure the holding oil pressure. a Measure the accumulator gas pressure (1) Ambient temperature20 C (2) Stop the engine and depress the brake pedal repeatedly until the operating effort becomes small to lower the oil pressure in the brake circuit to zero. Gas pressure (MPa {kg/cm2}) 4.41 {45.0} Holding oil pressure (MPa {kg/cm2}) Min. 14.7 {min. 150}

Defective brake charging pump system

5 Defective brake accumulator

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. 5 times or more (2) Turn the starting switch to the ON position and (normal) count the number of times needed to depress the brake pedal to let the brake caution lamp light up. a Measure the leakage from emergency parking brake valve Defective emergency parking 6 brake solenoid valve (1) Start the engine, confirm that the pressure has Oil leakage (cc) reached the accumulator charge valve cut-out pressure on the monitor, and then stop the Max. 80/minute (brake oil engine. temperature: 45 to 55 C) (2) Disconnect the return hose of solenoid valve and measure the amount of leakage from the hose. a Measure the leakage from brake valve 7 Defective brake valve (1) Start the engine, confirm that the pressure has Oil leakage (cc) reached the accumulator charge valve cut-out pressure on the monitor, and then stop the Max. 64/minute (brake oil engine. (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

Troubleshooting of hydraulic and mechanical system (H-mode) 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
Failure The lift arm moves slowly or the lift arm rising force is insufficient Ask the operator and check the following points (1) Does the work equipment speed suddenly become slower? Is any unusual noise heard at the time? And from where? (Breakage of related equipment)

40-714

Related infor(2) Does the speed become slower as the oil temperature rises? (Wear of related equipment) mation (3) Were there any symptoms of slow work equipment speed previously? (Wear of related equipment) a Check before troubleshooting: Check whether the level and type of oil in the hydraulic tank is appropriate. No. 1 Cause Procedure, measuring location, criteria and remarks

Defective work equipment control a Check for play due to wear or loosening and adjust as necessary. lever linkage a Engine speed can be checked with monitoring function. a E: Economy mode P: Power mode Engine speed Low idle High idle Torque converter stall Hydraulic stall (Lift arm RAISE relief) Hydraulic stall (Bucket TILT relief) Full stall (torque converter stall + hydraulic stall) E P E P E P E P Engine speed (rpm) 575 725 1,800 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,500 2,000 1,550 2,000 3.72 3.92 MPa {38 40 kg/cm2} 3.72 3.92 MPa {38 40 kg/cm2} Lift arm rising time (sec.) 20 23 36 39

2 Defective engine body

a PPC oil pressure can be checked with monitoring function.

q

3 Defective PPC oil pressure

Engine at high idle Work equipment relief Engine at high idle Work equipment relief

a Measure at lift arm RAISE PPC port of control valve

q

a Operation check of work equipment valve for work equipment speed

q q

Lift arm RAISE operation (ground level to max. height) Bucket with no load

Engine speed High idle Low idle

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 corresponding 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. 31.1 32.3 MPa q Engine at high idle q Bucket TILT relief {317 330 kg/cm2}

40-714

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) H-6 Lift arm speed is low or lift arm rising force is insufficient

No.

Cause

Procedure, measuring location, criteria and remarks a Measure the PV valve relief set pressure 2.8 3.2 MPa {28 32 kg/cm2} a Measure at ports P1 and P2 of ES valve for the No. 2 work equipment pump. Differential pressure Engine speed (MPa {kg/cm2}) q Forward 3rd or reverse 3rd Low idle 0 and brake pedals depressed
q

5 Defective PV control valve

Engine at high idle

Defective differential pressure valve

High idle a Measure cut-off solenoid valve outlet pressure.

0.5 0.6 {5 6}

Pressure at port P1 Pressure at port P1 when speed Max. 0.3 MPa exceeds 10 km/h while travelling {max. 3 kg/cm2} forward or reverse q Pressure at port P1 when speed is Min. 3 MPa below 10 km/h while travelling for{min. 30 kg/cm2} ward or reverse a If a defect in the electrical system of the solenoid circuit is suspected, perform troubleshooting according to "Open circuit, short circuit or hot short circuit in NEUTRAL cut solenoid".
q

Defective work equipment cut-off solenoid valve (NC valve)

a Measure ES valve outlet pressure ES valve outlet pressure

q

Defective work equipment pump 8 ES valve

While running the engine at high idle, move the bucket control lever slowly to the TILT direction and measure the ES valve outlet pressure when the differential pressure in step 6 is 0.33 MPa {3.35 kg/cm2}.

1.8 MPa {18.34 kg/cm2}

a Measure the CO cut-off pressure and CO output pressure of each pump CO valve oil pressure (MPa {kg/cm2}) Pump classification Cut-off Output Measure while running the enpressure pressure 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} NC valve oil pressure (MPa {kg/cm2}) Min. 2.0 {min. 20.0} Min. 2.0 {min. 20.0}

9 Defective CO valve

a Measure NC valve output pressure of each pump.

q q q

10 Defective NC valve

Pump classification Engine at low idle Work equipment lever is in No. 1 loader pump neutral (R) Directional selector switch "N" Switch pump (F)

WA1200-6

40-715

Troubleshooting of hydraulic and mechanical system (H-mode) H-6 Lift arm speed is low or lift arm rising force is insufficient

No.

Cause
q q

Procedure, measuring location, criteria and remarks a Measure hydraulic drift of work equipment. Hydraulic oil temperature: 45 Measuring position to 55 C Bucket hinge pin Stop the engine and leave it drop amount for five minutes, then take measurement for 15 minutes. Bucket cutting Bucket with no load edge drop amount With lift arm and bucket level Drop amount (mm) Max. 250 Max. 100 (Note)

11 Defective work equipment cylinder

q q

(Note) Does not include bucket hinge pin drop amount 12 Defective hydraulic pump Judge which hydraulic pump is defective by data obtained from above steps 4, 9, and 10.

40-716

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) H-7 Shock is large when lift arm stops

H-7 Shock is large when lift arm stops

Failure Shock is large when lift arm stops Ask the operator and check the following points (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? a Check before troubleshooting: Check whether the level and type of oil in the hydraulic tank is appropriate. No. 1 Cause Procedure, measuring location, criteria and remarks

40-717

Defective work equipment control 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 Lift arm RAISE, LOWER Bucket TILT, DUMP Orifice diameter f2.0 f10.0

2 Defective PPC valve outlet orifice

a Directly check the main control valve PPC port orifice 3 Defective main control valve PPC port orifice PPC port Lift arm LOWER Bucket TILT 4 Defective lift arm control lever detent switch Orifice diameter f2.6 f2.0

a If the lift arm control lever detent switch is suspected to be defective, perform troubleshooting by referring to the corresponding troubleshooting sheet. a Engine speed can be checked with monitoring function. a E: Economy mode P: Power mode Engine speed Low idle High idle Torque converter stall Hydraulic stall (Lift arm RAISE relief) Hydraulic stall (Bucket TILT relief) Full stall (torque converter stall + hydraulic stall) E P E P E P E P Engine speed (rpm) 575 725 1,800 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,500 2,000 1,500 2,000 3.72 3.92 MPa {38 40 kg/cm2} 3.72 3.92 MPa {38 40 kg/cm2}

5 Defective engine body

a PPC oil pressure can be checked with monitoring function.

q

6 Defective PPC oil pressure

Engine at high idle Work equipment relief Engine at high idle Work equipment relief

a Measure at lift arm RAISE PPC port of control valve

q q

WA1200-6

40-717

Troubleshooting of hydraulic and mechanical system (H-mode) H-8 Hydraulic oil temperature rises too high (overheating)

H-8 Hydraulic oil temperature rises too high (overheating)

Failure Hydraulic oil temperature rises too high (overheating) Ask the operator and check the following points (1) Does the hydraulic oil overheat suddenly? Is any unusual noise heard at the time? And from where? (Breakage of related equipment)

40-718

Related infor(2) In what working condition does it occur? During digging? mation 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) No. Cause Procedure, measuring location, criteria and remarks a Engine speed can be checked with monitoring function. a E: Economy mode P: Power mode Engine speed Low idle High idle Torque converter stall Hydraulic stall (Lift arm RAISE relief) Hydraulic stall (Bucket TILT relief) Full stall (torque converter stall + hydraulic stall) E P E P E P E P Engine speed (rpm) 575 725 1,800 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,650 2,000 1,700 2,000 1,500 2,000 1,550 2,000 3.72 3.92 MPa {38 40 kg/cm2}

1 Defective engine body

a PPC oil pressure can be checked with monitoring function.

q

2 Defective PPC oil pressure

Engine at high idle Work equipment relief

a Measure at lift arm RAISE PPC port of control valve 3.72 3.92 MPa Engine at high idle Work equipment relief {38 40 kg/cm2} 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 trend data. a If a failure code is displayed on the monitor, perform troubleshooting for it by referring to the corresponding troubleshooting sheet.
q q q

3 Defective operation

See failure code [B@HANS].

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 corresponding PPC port and measure the lift arm rising time for each condition a Measure the main relief set pressure of each valve a Main relief set pressure can be checked with monitoring function. 31.1 32.3 MPa q Engine speed: High idle q Bucket TILT relief {317 330 kg/cm2}

40-718

WA1200-6

Troubleshooting of hydraulic and mechanical system (H-mode) H-8 Hydraulic oil temperature rises too high (overheating)

No.

Cause
q q

Procedure, measuring location, criteria and remarks a Measure the air flow across the hydraulic oil cooler Engine speed: 1,900 rpm Average wind speed standard value 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 Difference in temperature between q Engine speed: High idle q Engine coolant temperature: Withcooler 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

5 Insufficient cooling air flow

6 Defective hydraulic oil cooler

Hydraulic oil cooler inlet pressure Defective hydraulic oil cooler cold 7 0.45 0.6 MPa Rated speed q Hydraulic oil cooler relief valve (1,900 rpm) oil temperature: 40 C {4.7 6.3 kg/cm2} 0.45 0.6 MPa High idle (2,050 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. Engine speed

WA1200-6

40-719

Troubleshooting of hydraulic and mechanical system (H-mode) H-8 Hydraulic oil temperature rises too high (overheating)

40-720

WA1200-6

SEN0547527-00

50-1

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

5-01

Machine model
WA1200-6

Serial number
60001 and up

50 Disassembly and assembly 50-1

WA1200-6

50-1

Contents

Contents
50 Disassembly and assembly General information on disassembly and assembly ............................................................... How to read Disassembly and Assembly............................................................................. Coating materials list............................................................................................................ Special tool list ..................................................................................................................... Sketches of special tools ..................................................................................................... Flushing procedure ................................................................................................................. Flushing procedure for brake circuit..................................................................................... Flushing procedure for work equipment and steering circuit ............................................... Air bleeding procedure............................................................................................................ Bleeding air from brake circuit ............................................................................................. Bleeding air from piston pump ............................................................................................. Bleeding air from work equipment circuit and steering circuit.............................................. Engine and cooling system ..................................................................................................... Removal and installation of radiator and hydraulic oil cooler assembly............................... Removal and installation of engine assembly...................................................................... Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly .............................................................................. Removal and installation of water-cooled torque converter and transmission oil cooler assembly ............................................................................................... Removal and installation of damper assembly .................................................................... Disassembly and assembly of damper ................................................................................ Removal and installation of bumper and fuel tank assembly............................................... Removal and installation of hood assembly......................................................................... Disassembly and assembly procedures for MESABI oil cooler ........................................... Disassembly and assembly of MESABI oil cooler ............................................................... Power train.............................................................................................................................. Removal and installation of torque converter and transmission assembly .......................... Disconnection and connection of transmission assembly and torque converter assembly . Disconnection and connection of torque converter assembly, PTO and transfer assembly Disassembly and assembly of torque converter .................................................................. Disassembly and assembly of modulation clutch ................................................................ Disassembly and assembly of PTO and transfer................................................................. Disconnection and connection of transmission assembly, transfer, and parking brake assembly .................................................................................................... Disassembly and assembly of transmission assembly ........................................................ Disassembly and assembly of transfer ................................................................................ Disassembly and assembly of parking brake....................................................................... Removal and installation of parking brake assembly (installed on the machine)................. Removal and installation of transmission, brake cooling device and brake pump assembly Removal and installation of steering pump, control pump and PPC pump assembly.......... Disassembly and assembly of drive shaft............................................................................ Removal and installation of front axle assembly.................................................................. Removal and installation of front final drive assembly ......................................................... Removal and installation of rear axle assembly................................................................... Removal and installation of rear final drive assembly.......................................................... Removal and installation of differential assembly ................................................................ Disassembly and assembly of differential............................................................................ Disassembly and assembly of final drive and brake ............................................................ Removal and installation of center support assembly.......................................................... Disassembly and assembly of center support ..................................................................... 5050505050505050505050505050504 4 6 9 14 54 54 60 66 66 68 69 72 72 79

50-2

50- 86 50- 88 50- 89 50- 91 50- 98 50- 100 50- 102 50- 105 50- 113 50- 113 50- 120 50- 127 50- 131 50- 142 50- 146 50- 159 50- 166 50- 187 50- 194 50- 197 50- 201 50- 202 50- 203 50- 205 50- 207 50- 209 50- 220 50- 223 50- 225 50- 238 50- 251 50- 253

50-2

WA1200-6

Contents

Steering system ...................................................................................................................... Removal and installation of steering demand valve assembly ............................................ Removal and installation of steering cylinder assembly ...................................................... Removal and installation of emergency diverter valve assembly ........................................ Removal and installation of emergency steering pump assembly ....................................... Brake system .......................................................................................................................... Removal and installation of brake accumulator charge valve assembly ............................. Removal and installation of brake oil tank assembly ........................................................... Undercarriage and frame ........................................................................................................ Procedure for disconnecting front frame and rear frame ..................................................... Removal and installation of center hinge pin ....................................................................... Hydraulic system .................................................................................................................... Removal and installation of hydraulic tank, filter case assembly......................................... Removal and installation of No. 1 work equipment pump assembly ................................... Removal and installation of No. 2 work equipment pump assembly ................................... Removal and installation of switch pump assembly ............................................................ Removal and installation of work equipment control valve assembly .................................. Work equipment...................................................................................................................... Removal and installation of bucket cylinder assembly ........................................................ Removal and installation of lift cylinder assembly ............................................................... Disassembly and assembly of work equipment cylinder ..................................................... Removal and installation of work equipment assembly ....................................................... Procedure for running in bucket pin..................................................................................... Procedure for running in lift arm pin..................................................................................... Cab ......................................................................................................................................... Removal and installation of bulkhead assembly .................................................................. Removal and installation of operator's cab and floor assembly........................................... Removal and installation of operator's cab assembly.......................................................... Removal and installation of air conditioner unit assembly ................................................... Disassembly and assembly of operator seat ....................................................................... Electrical system ..................................................................................................................... Removal and installation of DT connector pin ..................................................................... Removal and installation of HD connector pin..................................................................... Repairing HD connector pin harness................................................................................... Removal and installation of controller assembly..................................................................

50- 257 50- 257 50- 258 50- 262 50- 264 50- 265 50- 265 50- 266 50- 267 50- 267 50- 268 50- 284 50- 284 50- 286 50- 288 50- 289 50- 290 50- 304 50- 304 50- 315 50- 329 50- 335 50- 391 50- 393 50- 396 50- 396 50- 398 50- 402 50- 404 50- 406 50- 439 50- 439 50- 441 50- 442 50- 443

WA1200-6

50-3

General information on disassembly and assembly How to read Disassembly and Assembly

General information on disassembly and assembly

How to read Disassembly and Assembly
1. Removal and installation of assemblies Special tools 50-4 q Special tools which are necessary for removal or installation of parts are described as A1 ..... X1, etc. and their part numbers, part names and quantities are described in the special tool list. q In the special tools table, the following information is described, as well as the above items. 1) Necessity t: Special tools that cannot be substituted and should always be used. q: Special tools that will be useful if available and are substitutable with tools available on the market. 2) 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 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 presented 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). 50-4 Removal In "Removal" 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 Common tools that are necessary for removal are described as [1], [2] etc. and their part numbers, part names and quantities are not described. q Various symbols used in "Removal" section are explained and listed below. k :This mark indicates safety-related precauq

50-4
(Rev. 2009. 01) 50-4

50-4

[*1] : This mark shows that instructions or precautions for parts installation work are given in "Installation" section. 6 : Amount of oil or coolant to be drained. 4 : Weight of part or component 50-4 Installation Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation are shown with the mark (e.g.[*1]) which corresponds to the mark in "Removal" section. q Common tools that are necessary for installation are described as [1], [2] etc. and their part numbers, part names and quantities are not described. q Marks shown in the "Installation" section stand for the following. k : Precautions related to work safety a : Know-how or precautions for work 2 : Type of coating material 3 : Tightening torque 5 : This mark indicates the amount of oil or coolant to be added.
q

50-4 Sketches of special tools Various special tools are illustrated for the local manufacture.

tions which must be followed when doing the work.

a : Know-how or precautions for work

50-4

WA1200-6

General information on disassembly and assembly How to read Disassembly and Assembly

2. Disassembly and assembly of assembly Special tools 50-5 q Special tools which are deemed necessary for disassembly or assembly of parts are described as A1? ..... X1, etc. and their part names, part numbers and quantities are described in the special tool list. q In the special tools list, the follwing information is described, as well as the above items. 1) Necessity t: Special tools that cannot be substituted and should always be used. q: Special tools that will be useful if available and are substitutable with tools available on the market. 2) 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 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 presented 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). 50-5 Disassembly 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 disassembly are described as [1], [2]etc. and their part names, part numbers and quantities are not described. q The meanings of the symbols used in "Disassembly" 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.
q

50-5 50-5 Assembly q In "Assembly" section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q General tools that are necessary for assembly are described as [1], [2] etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in "Assembly" section are as follows. k :This mark indicates safety-related precautions which must be followed when doing the work.

a : Know-how or precautions for work 2 : Type of coating material 3 : Tightening torque 5 : This mark indicates the amount of oil or coolant to be added. 50-5 Sketches of special tools Various special tools are illustrated for the local manufacture.

WA1200-6

50-5

General information on disassembly and assembly 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 disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual.
Category Komatsu code LT-1A LT-1B Part number 790-129-9030 790-129-9050 Capacity 150 g Container Tube
q q

Main features and applications Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out. Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion. Features: Resistance to heat and chemicals Use to fix and seal bolts and plugs. Use to bond and seal metal, glass and plastics.

20 g Polyethyl(2 pcs. con- ene contained) tainer 50 g Adhesive: 1 kg Hardener: 500 g 250 g 75 g 50 g Polyethylene container Can Polyethylene container Tube Polyethylene container Polyethylene container

LT-2

09940-00030 790-129-9060 (Set of adhesive and hardener) 790-129-9040 790-126-9120 790-129-9140

q q

LT-3

LT-4 Adhesive Holtz MH 705 Three Bond 1735

q q q q q q q q q

Use to seal plugs for blank holes. Heat-resistant seal used to repair engines Instanetaneous adhesive Curing time: From 5 sec. to 3 min. Use mainly to bond metals, rubbers, plastics, and woods. Instanetaneous adhesive Quick-curing type (max. strength is obtained after 30 minutes) Use mainly to bond rubbers, plastics, and metals. General-purpose instantaneous adhesive with excellent resistance to heat and impact Use on the bushing mounting faces of axle supports. Features: Resistance to heat and chemicals Use for fitted portions exposed to high temperatures. Use to seal various threaded portions, pipe joints, and flanges. Use to seal taper plugs, elbows, and nipples for hydraulic piping. Features: Silicon-based heat and cold-resistant sealant. Use to seal threaded portions and flange surface Use to seal oil pan, final drive case, etc. Features: Silicon-based quick-curing sealant Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc. Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant Use to seal transfer case, etc. Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc. Can be coated with paint.

Aron-alpha 201

790-129-9130

2g

LOCTITE 499

428-99-80070

20 g

Tube Polyethylene container Polyethylene container Tube

q q q q q q

LOCTITE 648-50

79A-129-9110

50 cc

LG-5

790-129-9080

1 kg

LG-6 Liquid gasket

790-129-9160

200 g

q q q

LG-7

790-129-9170

1 kg 100 g

Tube Tube

q q q q

LG-8 419-15-18131 Three Bond 1207B LG-9 790-129-9310 Three Bond 1206D

200 g

Tube
q

50-6

WA1200-6

General information on disassembly and assembly Coating materials list

Category Liquid gasket

Komatsu code

Part number

Capacity 200 g

Container
q

Main features and applications Use as lubricant or sealant when the radiator hoses are put on. Can be coated with paint. Feature: Can be used together with solid gaskets. Use for covers of the transmission case and steering case etc. Liquid gasket used to repair engine Use to prevent galling and seizure of press-fitted portions, shrinkage-fitted portions, and threaded portions. Use to lubricate linkages, bearings, etc. Spray type Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from galling. Use for the drive shaft splines, needle bearings, various link pins, bolts, etc. Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc. Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

LG-10 790-129-9320 Three Bond 1206E LG-11 Three Bond 1121 Three Bond 1211 790-129-9330 790-129-9090 09940-00040

Tube
q q

200 g 100 g 200 g

Tube Tube Tube

q q q

Molybdenum disulphide lubricant

LM-P

q q q

09995-00250

190 g

Can
q

Seizure prevention compound

LC-G NEVER-SEEZ

Can

SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI(*) SYGA-160CNLI *: For cold regions SYG0-400LI-A (*) SYG0-16CNLI (*) Molybdenum disul- SYG2-400M phide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM Grease SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

Various

Various

Lithium grease with extreme pressure lubrication performance, general purpose type.

q Use for parts under heavy load. Caution: 400 g 10 Belq Do not use this grease for rolling bearings like 400 g 20 lows-type swing circle bearings, etc. and spline. 16 kg container q Use this grease for work equipment pins only Can when installing them, but do not use it afterward.

Hyper White G2-T G0-T(*) *: For cold regions Biog rease G2-B G2-BT(*) *: For use at high temperature and under high load G2-S Three Bond 1855

400 g 16 kg

Bellows-type container Can Bellows-type container Can

Higher seizure resistance, heat resistance and water resistance than molybdenum disulphide grease. Not conspicuous on machine since color is white. Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants. Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. Use for oil seals of the transmission, etc.

400 g 16 kg

200 g

Tube
q

WA1200-6

50-7

General information on disassembly and assembly Coating materials list

Category Grease

Komatsu code G2-U-S ENS grease LOCTITE 712 SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER

Part number

Capacity

Container
q

Main features and applications Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. Use for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease. Use to accelerate hardening of instantaneous adhesive. q Use as primer for painted cab sheet metal surface. (Effective period: four months after manufacture) q Use as primer for cab glass surface. (Effective period: four months after manufacture) q Use as primer for painted cab sheet metal surface. (Effective period: four months after manufacture) q Use as primer for black ceramic-coated glass surface and for hard polycarbonate-coated surface. (Effective period: four months after manufacture) q Use as primer for sash (Almite). (Effective period: four months after manufacture) q Use S" in high-temperature season and W" in low-temperature season as adhesive for glass. (Effective period: four months after manufacture) q Use as adhesive for glass. (Effective period: six months after manufacture)
q

427-12-11871 428-99-80080

2 kg 100 ml 20 ml

Can Glass container Glass container Glass container Glass container

q q

417-926-3910 20 ml

Primer

SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41 SUNSTAR PRIMER GP-402 for sash

22M-54-27230

20 ml

22M-54-27240

150 ml

Steel can For adhered window glass

22M-54-27250

20 ml

Glass container Polyethylene container Polyethylene container Ecocart (Special container) Polyethylene container Polyethylene container Cartridge

Adhesive

SUNSTAR PENGUINE SEAL 417-926-3910 580 SUPER "S" or "W" Sikaflex 256HV manufactured by Sika Japan SUNSTAR PENGUINE SUPER 560 20Y-54-39850

320 ml

310 ml

22M-54-27210

320 ml

Use as adhesive for glass. (Effective period: six months after manufacture) Use to seal joints of glass parts. (Effective period: four months after manufacture) Use to seal front window. (Effective period: six months after manufacture) Use to seal joint of glasses. Translucent white seal. (Effective period: 12 months after manufacture)

Caulking material

SUNSTAR PENGUINE SEAL 417-926-3920 No. 2505 SEKISUI SILICONE SEALANT 20Y-54-55130

320 ml 333 ml

GE TOSHIBA SILICONES 22M-54-27220 TOSSEAL381

333 ml

50-8

WA1200-6

General information on disassembly and assembly 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 modification a Tools marked with Q in the sketch column are presented in the sketches of the special tools. (See "Sketches of special tools") a Tool part No. SMT QQQ-QQQ means that the tool is to be made locally and not specified as a special tool (i.e., the price is not set). Therefore, such a tool is not available from Komatsu Ltd.
Q'ty New/redesign Sketch Q 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 N N N N N N Q Q Q Q Q Q Q

Work

Symbol

Part No.

Part name

Necessity

Detail of work, remarks

Removal and installaA tion of engine assembly

1 SMT-890-5200 Lifting tool assembly 1-1 SMT-890-5210 q Frame Commercially q Single sling 1-2 available 1-3 Commercially available
q

t 1 t 1 q 4 q 1 t t t t t t t t t t t t t t t t t t

Sling for engine assembly (S-SLSL f10 , L = 1.5 m, manufactured by KITO) (GD-4N f12.5x4 , L = 2 m, manufactured by KITO)

Quad sling

Disassembly and assembly of damper

1 SMT-890-1830 Spacer 2 SMT-890-1710 Sleeve 3 SMT-890-1810 Push tool 790-201-2100 Push tool 4 790-201-2390 q Plate 5 SMT-890-5010 Lifting tool 6 790-101-3701 SMT-890-1200 1 SMT-890-1210 SMT-890-1220 2 SMT-890-1230 3 SMT-890-1240 SMT-890-1250 Gear puller Assembly drawing q Socket q Guide Socket Test/J Test/J

Q Press fit of bearing Q Q Press fit of oil seal

t 1

Sling for damper cover and damper assembly Removal of spacer Press fit of retainer oil seal

Disassembly and assembly of modulation clutch, and disassemC bly and assembly of PTO and transfer

4 SMT-890-1310 Wrench SMT-890-5600 Assembly drawing SMT-890-5610 q Gear 5 SMT-890-5620 q Shaft SMT-890-5630 q Carburetor SMT-890-5640 q Plate 6 SMT-890-5710 Test jig

t 1

Press fit of bearing Preload adjustment of input gear bearing Removal and installation of Q modulation clutch piston nut Q Q Q Preload adjustment of input Q gear bearing Q Q

WA1200-6

50-9

General information on disassembly and assembly Special tool list

Work

Symbol

Q'ty New/redesign Sketch Q 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 Q Q Q Q

Necessity

Part No.

Part name

Detail of work, remarks

1 SMT-890-1410 Socket SMT-890-1500 Assembly drawing 2 SMT-890-1510 q Socket SMT-890-1520 q Guide Disassembly and assembly of transmission, disassembly and assembly of transfer, and disassembly and assembly of parking brake 3 SMT-890-1530 Socket D 4 SMT-890-1540 Socket 5 SMT-890-1550 Socket 6 SMT-890-1560 Socket 7 790-302-1280 Socket (Width across flats: 55 mm) Puller Puller Pump q Guide q Guide q Guide q Guide q Guide q Plate q Bolt q Washer q Nut q Guide q Guide q Guide q Guide q Bolt q Washer q Nut Puller Pump Push tool q Sleeve q Sleeve q Plate q Guide q Guide q Bolt q Washer q Nut Push tool Push tool Push tool Push tool

t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t 1 t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t

8 SMT-890-4100 Guide 790-314-1000 790-101-4000 790-101-1102 SMT-890-2100 SMT-890-2110 SMT-890-2120 SMT-890-2150 SMT-890-2160 SMT-890-2170 1 SMT-890-2180 01643-33690 01580-03629 SMT-890-2130 SMT-890-2140 SMT-890-2210 SMT-890-2220 791-775-1140 01643-33080 01582-03024 790-101-4000 790-101-1102 SMT-890-2300 SMT-890-2310 SMT-890-2320 2 SMT-890-2330 SMT-890-2210 SMT-890-2220 791-775-1140 01643-33080 01532-03024 SMT-890-2410 SMT-890-2420 3 SMT-890-2430 SMT-890-2440

Q Press fit of transfer output Q shaft oil seal Q Press fit of transfer output Q shaft dust seal Press fit of transfer output Q shaft coupling cover Press fit of transfer output Q shaft bearing Support for transfer output Q shaft Removal and installation of transfer coupling bolt Insertion of R, and F and 3rd Q clutch carrier pinion shafts

Press fit of transmission front housing bearing

Q Q Q Q Q Q Q Press fit of bearing

Removal and installation of center hinge pin

Q Q Q Press fit of bushing Q (In common with K1) Q (In common with K1) Q

Removal and installation of center hinge pin

Q Q Press fit of dust seal Q Q

50-10

WA1200-6

General information on disassembly and assembly Special tool list

Work

Symbol

Part No.

Part name

Q'ty New/redesign Sketch Q 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Necessity

Detail of work, remarks

Removal and installation of front and rear axles

793T-870-141 stand 0 793T-870-142 2 stand 0 793T-870-143 3 stand 0 1 4 SMT-890-5020 Plate 5 SMT-890-5030 Plate 6 SMT-890-5040 Plate 792-340-1120 796-550-1310 792-525-3000 2 790-425-1670 790-425-1660 SMT-890-3100 SMT-890-3110 3 SMT-890-3120 SMT-890-3130 SMT-890-3140 SMT-890-5100 SMT-890-5110 SMT-890-5120 04025-00850 4 01252-61675 1 Nut wrench Wrench Micrometer Adapter Wrench Tool assembly q Cylinder q Piston q Shaft q Plate Handle assembly q Handle q Flange q Parallel pin q Hexagon socket head bolt q Hexagon socket head 01252-62045 bolt 01580-31613 q Nut 5 SMT-890-1910 Installer

q 1 q 1 q 1 q 1 q 1 q 1 t t t t t t t t t t t t t t

Q Support for front frame Q Support for rear frame Q Support for rear frame Locking of axle mount bolt (for front axle) Locking of axle mount bolt Q (for rear axle, front) Locking of axle mount bolt Q (for rear axle, rear) Removal and installation of sleeve nut Preload adjustment of side bearing Q Q Preload adjustment of hub Q bearing Q Q Q Q Q Installation of axle shaft

Disassembly and assembly of differential, and disassembly and J assembly of final drive and brake

t 2 t 1 t 1 t 1

Q Installation of floating seal

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General information on disassembly and assembly Special tool list

Work

Symbol

Q'ty New/redesign Sketch 1 1 2 1 1 1 4 1 4

Necessity

Part No.

Part name

Detail of work, remarks

SMT-890-5480 Bolt 1 SMT-890-5491 Nut SMT-890-5471 Nut SMT-890-5300 Push puller assembly SMT-890-5310 q Plate SMT-890-5320 q Guide bar SMT-890-5330 q Flange nut SMT-890-5340 q Push bolt 3 SMT-890-5350 SMT-890-5360 SMT-890-5370 4 SMT-890-5050 SMT-890-5070 SMT-890-5060 5 SMT-890-5070
q q q

q 2 q 2 q 2 q 2 q q q q q

2 SMT-890-5460 Bolt

Leveling pad Adapter Adapter

q 1 q 2 q 2 q q q q

Removal and installation of work equipment assembly

Plate Bolt Plate Bolt

T 10 42C-98-11320 Plate 11 42C-98-11330 Plate 12 42C-98-11340 Plate 13 01017-51245 01011-81265 Bolt Bolt

q 1 q 1 q 1 q 2 q 2

Q Removal of work equipment pin Q (for f180 pins) Q Removal of work equipment pin Q (for f240 and 280 pins) Q Q Installation of work equipment Q pin Q Q (P-16) (Commercially availQ able) For pin mounting bolt hole of Q 30 mm in diameter (*1) For pin mounting bolt hole of Q 24 mm in diameter (*2) Removal of collar (for f180 and 240 pins) Q Removal of collar Q (for f280 pins) Collar stopper plate for f180 Q pin Collar stopper plate for f240 Q pin Collar stopper plate for f280 Q pin Collar tap bolt for pins of any size Collar stopper plate tap bolt (for joint of lift arm and bucket) Collar stopper plate tap bolt (for joint of bucket link and bucket) Collar stopper plate tap bolt (for joint of lift arm and bell crank) Collar stopper plate tap bolt (for joints other than the above three joints) Fixing plate for press fit of Q bushing

01011-81250 14 01011-81230

Bolt

q 2

Bolt

q 2

01010-81230

Bolt

q 2 q 1

15 42C-98-11350 Plate

*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

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General information on disassembly and assembly Special tool list

Work

Symbol

Q'ty New/redesign Sketch

Necessity

Part No.

Part name

Detail of work, remarks

2 790-502-1003 Cylinder repair stand 3 790-720-1000 Expander Disassembly and assembly of hydraulic cylinder 796-720-1720 Ring U 4 07281-02429 Clamp

q 1 q 1 q 1 q 1 q 1 q 1 q 1

Disassembly and assembly of hydraulic cylinder Installation of piston ring (For steering cylinder) (Piston diameter: 225 mm) (For lift cylinder) (Piston diameter: 360 mm) (For bucket cylinder) (Piston diameter: 300 mm) Disassembly and assembly of steering cylinder piston

796-720-1730 Ring 07281-03209 Clamp

5 790-102-3902 Wrench

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General information on disassembly and assembly Sketches of special tools

Sketches of special tools

50-14

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-14 A1-1 Frame

B1 Spacer

50-14

50-14

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-15 B2 Sleeve

B3: Push tool

50-15

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50-15

General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-16 B5 Lifting tool

C1 (1/3) Assembly drawing

50-16

50-16

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-17 C1 (2/3) Socket

C1 (3/3) Guide

50-17

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-18 C2 Socket

C3 (1/2) Test jig

50-18

50-18

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-19 C3 (2/2) Test jig

C4. Wrench

50-19

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-20 C5 (1/5) Assembly drawing

C5 (2/5) Gear

50-20

50-20

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-21 C5 (3/5) Shaft

C5 (4/5) Cap

50-21

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-2 C5 (5/5) Plate

C6 Test jig

50-2

50-22

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-23 D1 Socket

D2 (1/3) Assembly drawing

50-23

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50-23

General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-24 D2 (2/3) Socket

D2 (3/3) Guide

50-24

50-24

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-25 D3 Socket

D4 Socket

50-25

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50-25

General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-26 D5 Socket

D6 Socket

50-26

50-26

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-27 D8 Guide

K1 (1/11) Push tool

50-27

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-28 K1 (2/11) Guide

K1 (3/11) Guide

50-28

50-28

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-29 K1 (4/11) Guide

K1 (5/11) Guide

50-29

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-30 K1 (6/11) Guide

K1 (7/11) Guide

50-30

50-30

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-31 K1 (8/11) Plate

K1 (9/11) Bolt

50-31

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-32 K1 (10/11) Guide

K1 (11/11) Guide

50-32

50-32

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-3 K2 (1/4) Push tool

K2 (2/4) Sleeve

50-3

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50-33

General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-34 K2 (3/4) Sleeve

K2 (4/4) Plate

50-34

50-34

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-35 K3 (1/4) Push tool

K3 (2/4) Push tool

50-35

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-36 K3 (3/4) Push tool

K3 (4/4) Push tool

50-36

50-36

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-37 L1 Stand

L2 Stand

50-37

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-38 L3 Stand

L4 Plate

50-38

50-38

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-39 L5 Plate

L6 Plate

50-39

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-40 J3 (1/5) Tool assembly

J3 (2/5) Cylinder

50-40

50-40

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-41 J3 (3/5) Piston

J3 (4/5) Shaft

50-41

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-42 J3 (5/5) Plate

J4 (1/3) Handle assembly

50-42

50-42

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-43 J4 (2/3) Handle

J4 (3/3) Flange

50-43

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50-43

General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-4 J5 Installer

50-44

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-45 T1 (1/2) Bolt

T1 (2/2) Nut

50-45

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-46 T2 (1/2) Bolt

T2 (2/2) Nut

50-46

50-46

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-47 T3 (1/8) Push puller assembly

T3 (2/8) Plate

50-47

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-48 T3 (3/8) Guide bar

T3 (4/8) Flange nut

50-48

50-48

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-49 T3 (5/8) Push bolt

T3 (6/8) Leveling pad

50-49

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50-49

General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-50 T3 (7/8) Adapter (for 30 mm)

T3 (8/8) Adapter (for 24 mm)

50-50

50-50

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-51 T5 (1/2) Plate

T5 (2/2) Bolt

50-51

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-52 T10 Plate

T11 Plate

50-52

50-52

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General information on disassembly and assembly Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches. 50-53 T12 Plate

T15 Plate

50-53

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50-53

Flushing procedure Flushing procedure for brake circuit

Flushing procedure
Selection of flushing pattern
Pattern A B

Flushing procedure for brake circuit

Contamination level When replacing a damaged internal part of a hydraulic component When flushing a hydraulic circuit that has failed in the past but is working properly When flushing a hydraulic circuit that has not failed in the past and is working properly

50-54

50-54

Work outline for each pattern

No. Work item Cleaning of each hydraulic component
q

Pattern A B Q Q Q Q Q Q Q Q Q Q Q

Hydraulic pump Valves Hydraulic tank Brake oil cooler Hydraulic tubes and hoses

q q q q

2 Flushing of hydraulic circuits 3 Replacement of hydraulic oil 4 Replacement of element

50-54

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Flushing procedure Flushing procedure for brake circuit

Parts used for flushing

No. Work item Part No. 07063-41187 07063-51035 208-60-61180 07063-51035 21T-60-13680 421-43-27920 07002-25234 566-60-15361 42C-03-15110 Pattern A B 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 Flushing element 2 Standard element 3 Filter and bypass circuit closing plate

4 In-line filter strainer 5 O-ring 11 Breather 12 Brake oil cooler

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Flushing procedure Flushing procedure for brake circuit

50-56 Flushing procedure (Flushing pattern A) 50-56 1. Check that the following components are disassembled, 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 available. 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 fragments 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 severely, 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

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Flushing procedure Flushing procedure for brake circuit

2. Preparation for flushing 1) Replace filter elements (F1) and (F2) in the brake oil tank with flushing elements. 2) Replace bypass valves (B1) and (B2) with bypass circuit closing plates.

3) Start and run the engine at low idle. After the brake oil pressure warning lamp goes off, "press" and "release" the brake pedal repeatedly for 10 minutes at an interval of 3 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 repeatedly for 10 minutes at an interval of 3 seconds. 6) Stop the engine and "press" and "release" the brake pedal repeatedly at an interval of 3 seconds until accumulator pressure is relieved. 7) Start and run the engine at high idle. After the brake oil pressure warning lamp goes off, "press" and "release" the brake pedal repeatedly for 10 minutes at an interval of 3 seconds. 8) Stop the engine and "press" and "release" the brake pedal repeatedly at an interval of 3 seconds until accumulator pressure is 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 one.

Replace bypass valves (B1) and (B2) with 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
q

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. 2) Stop the engine and "press" and "release" the brake pedal repeatedly at an interval of 3 seconds until accumulator pressure is relieved.

4) Add hydraulic oil (new oil) to the specified level.

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Flushing procedure Flushing procedure for brake circuit

(Flushing pattern B) 1. Drain the oil from the hydraulic tank.

50-58

2. Preparation for flushing 1) Replace filter elements (F1) and (F2) in the brake oil tank with flushing elements. 2) Replace bypass valves (B1) and (B2) with bypass circuit closing plates.

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. 2) Stop the engine and "press" and "release" the brake pedal repeatedly at an interval of 3 seconds until accumulator pressure is relieved. 3) Start and run the engine at low idle. After the brake oil pressure warning lamp goes off, "press" and "release" the brake pedal repeatedly for 10 minutes at an interval of 3 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 repeatedly for 10 minutes at an interval of 3 seconds. 6) Stop the engine and "press" and "release" the brake pedal repeatedly at an interval of 3 seconds until accumulator pressure is relieved. 7) Start and run the engine at high idle. After the brake oil pressure warning lamp goes off, "press" and "release" the brake pedal repeatedly for 10 minutes at an interval of 3 seconds. 8) Stop the engine and "press" and "release" the brake pedal repeatedly at an interval of 3 seconds until accumulator pressure is relieved. 4. Check of element Perform one cycle of steps 1) to 8) and check the element. If the element is contaminated, clean it and perform one flushing cycle again.

Replace bypass valves (B1) and (B2) with 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
q

50-58

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Flushing procedure Flushing procedure for brake circuit

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.

4) Add hydraulic oil (new oil) to the specified level.

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Flushing procedure Flushing procedure for work equipment and steering circuit

Flushing procedure for work equipment and steering circuit

Selection of flushing pattern
Pattern A B C Contamination level When replacing a damaged internal part of a hydraulic component When flushing a hydraulic circuit that has failed in the past but is working properly When flushing a hydraulic circuit that has not failed in the past and is working properly Pattern A B C Q Q Q Q Q Q Q Q Q Q Q Q Q Q

50-60

Work outline for each pattern

No. Work item Cleaning of each hydraulic component q Hydraulic pump q Valves q Hydraulic cylinder q Hydraulic tank q Hydraulic oil cooler q Hydraulic tubes and hoses Short-circuit flushing of hydraulic circuits q Lift arm cylinder circuit q Bucket cylinder circuit q Steering cylinder circuit Replacement of hydraulic oil Replacement of element

2 3 4

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Flushing procedure Flushing procedure for work equipment and steering circuit

Parts used for flushing

No. Work item 1 Flushing element 2 Standard element 3 Short-circuit flange Pattern A B C 07063-41187 3 208-60-61180 3 3 3 F2 2 2 F3 4 4 209-60-12840 2 2 2 Part No.

4 PPC element Filter and bypass cir5 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.)

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Flushing procedure Flushing procedure for work equipment and steering circuit

50-62 Flushing pattern A 1. Check that the following components are disassembled, cleaned, and re-installed. 1) Replace the parts that caused a problem with new ones. 2) Disassemble, clean, and assemble each 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.

2. 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) Replace suction strainer (4) with a new one.

5) Remove the hydraulic hoses and hydraulic tubes from the machine and clean them. 6) Install the disassembled, cleaned, and assembled parts to the machine.

4) Connect the inlet and outlet hoses of the hydraulic cylinders by using tools F2 and F3 (short-circuit flanges) to short-circuit the hydraulic circuit. 5) Add hydraulic oil to the specified level in the hydraulic tank. 5 Hydraulic tank: 1200 l 3. Perform flushing according to 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 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.

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Flushing procedure Flushing procedure for work equipment and steering circuit

3) Run the engine at the full speed and operate the levers according to the following procedure. 1] Move the steering lever to the right and hold it there for 2 minutes. 2] Move the steering lever to the left and hold it there for 2 minutes. 3] Move the lift arm lever to RAISE and hold it there for 2 minutes. 4] Move the lift arm lever to LOWER and hold it there for 2 minutes. 5] Move the bucket lever to TILT and hold it there for 2 minutes. 6] Move the bucket lever to DUMP and hold it there for 2 minutes. 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.

5) Add hydraulic oil to the specified level. 6) Replace in-line filter strainers (6) and (7) with new ones.

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Flushing procedure Flushing procedure for work equipment and steering circuit

50-64 Flushing pattern B 1. Drain the oil from the hydraulic tank. 2. Remove the strainer of the hydraulic tank. 3. 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) Connect the inlet and outlet hoses of the hydraulic cylinders by using tools F2 and F3 (short-circuit flanges) to short-circuit the hydraulic circuit. 4) Add hydraulic oil to the specified level in the hydraulic tank. 5 Hydraulic tank: 1200 l 4. Perform flushing according to 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 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. 3) Run the engine at the full speed and operate the levers according to the following procedure. 1] Move the steering lever to the right and hold it there for 2 minutes. 2] Move the steering lever to the left and hold it there for 2 minutes. 3] Move up the lift arm lever to RAISE and hold it for 2 minutes. 4] Move the lift arm lever to LOWER and hold it there for 2 minutes. 5] Move the bucket lever to TILT and hold it there for 2 minutes. 6] Move the bucket lever to DUMP and hold it there for 2 minutes. 4) Repeat steps 1) to 6) 5 times or more.

5. 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 filter bypass circuit closing plates and install the bypass valve. 4) Replace PPC element (5) with a new one.

50-64

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Flushing procedure Flushing procedure for work equipment and steering circuit

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. 2. Perform flushing according to 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 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. 3) Run the engine at the full speed and operate the levers according to the following procedure. 1] Move the steering lever to the right end and then to the left end. Repeat this operation ten times. 2] Move the lift arm lever to RAISE end and then to LOWER end. Repeat this operation 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.

5) Replace in-line filter strainers (6) and (7) with new ones.

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Air bleeding procedure Bleeding air from brake circuit

Air bleeding procedure

Bleeding air from brake circuit

Bleeding air from wheel brake circuit 50-6

50-6

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 following 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

Air bleeding procedure Bleeding air from brake circuit

Bleeding air from brake pump circuit

50-67

1. Check that the oil level in the brake oil tank is HIGH. 2. Bleed air from the wheel circuit. For details, see "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 returned to the original positions.

6. Check again the oil level in the brake oil tank. Add oil if necessary. 7. Depress the brake pedal to check that the brake circuit operates normally and that the brake charge cut-in and cut-out pressures are normal.

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

Air bleeding procedure Bleeding air from piston pump

Bleeding air from piston pump

a When the oil in the hydraulic tank is replaced, when the piston pump is replaced, or when piping of the piston pump is removed, bleed air according to the following procedure to prevent pump seizure. 1. Preparation 1) Remove plug (5) on the side of the breather and connect an air-pressurization coupler and an air hose. 2) Add oil to the dipstick level (H level) in the tank. (Oil type: EO10-CD)

50-68
2. Bleeding air from piston pump 1) Loosen air bleeding plugs (1), (2), (3), and (4) on the top of the tube on the suction side of the piston pump. 2) 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 plugs. 3) When the oil overflows from the plugs and air 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 pressurization and tighten the hose fittings.

50-68

WA1200-6

Air bleeding procedure Bleeding air from work equipment circuit and steering circuit

Bleeding air from work equipment circuit and steering circuit

q

50-69

Bleeding air from work equipment oil circuit a When the hydraulic oil control valve or work equipment cylinder has been removed and reinstalled, bleed the system of air by following the procedure given below. 1. Supply the hydraulic tank with oil until the oil level reaches the window of the sight gauge (1).

5. Run the engine at low idle. 1) Slowly move the lift arm and bucket cylinder piston rod to the position just before the stroke end. q Never let the relief valves actuate. q Raise and lower the lift arm and tilt and dump the bucket four to five times repeatedly. 2) Slowly move the lift arm and bucket cylinder to the stroke end. q Never let the relief valves actuate. q Raise and lower the lift arm and tilt and dump the bucket four to five times repeatedly. 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) When disassembling or reassembling the work equipment, valves, or piping, check the air bleeding plugs before starting the engine, and replace any damaged plug with a new one.

2. Add oil 400 l further. 3. Tighten cap (4).

4. Start and run the engine at low idle for five minutes. Check for oil leaks. 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

Air bleeding procedure Bleeding air from work equipment circuit and steering circuit

7. Lower the bucket to the ground and check the oil level. Then, add oil up to the window of the sight gauge (1).

Bleeding air from steering oil circuit a Bleed air from the oil circuit as follows if the 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 Never let the relief valves actuate. q Raise and lower the lift arm and tilt and dump the bucket four to five times repeatedly. 9. Stop the engine, loosen plugs (1) to (4) to bleed 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).

2. Add oil of 400 l further. 3. Tighten cap (4).

4. Start and run the engine at low idle for five minutes. Check for oil leaks. 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

Air bleeding procedure Bleeding air from work equipment circuit and steering circuit

5. Run the engine at low idle. 1) Slowly move each cylinder rod back and forth until it comes to 100 mm before the stroke end. q Never let the relief valves actuate. q Steer alternately to right and left four or five times. 2) Slowly move each cylinder rod back and forth to its stroke ends. q Never let the relief valves actuate. q Steer alternately to the 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 plug with a new one.

8. Run the engine at 1,500 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 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).

7. Lower the bucket to the ground and check the oil level. Then, add oil up to the window in the sight gauge (1).

WA1200-6

50-71

Engine and cooling system Removal and installation of radiator and hydraulic oil cooler assembly

Engine and cooling system

Removal and installation of radiator and hydraulic oil cooler assembly 50-72
Removal 50-72 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 1. Drain the engine coolant. 6 Coolant: 6. Disconnect two hydraulic oil cooler pipes (5).

50-72

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). 5. Sling radiator guard (3), and remove mounting bolt (4) to remove the radiator guard. [*1] 4 Radiator guard: 970 kg 7. Disconnect radiator outlet tube (6). 8. Disconnect coolant drain hose (7). 9. Disconnect hose clamp (8).

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).

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WA1200-6

Engine and cooling system Removal and installation of radiator and hydraulic oil cooler assembly

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 assembly: 2,900 kg

WA1200-6

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Engine and cooling system Removal and installation of radiator and hydraulic oil cooler assembly

Installation
q

50-74

2) Fix the baffle assembly with eight mounting bolts (29).

perform installation in the reverse order to removal.

When the radiator assembly is removed, use the following steps to install the radiator baffles before 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 radiator and oil cooler assembly to the machine.
k

Perform this work on the oil cooler placed on the floor. Never perform this work while slinging the oil cooler.

2. Installing radiator and oil cooler Install the radiator and oil cooler assembly to the machine. 3. Top face of fan guard 1) Stick sheets (31) and (32) on baffle (30), and install the baffle assembly to the top face of the rear oil cooler. 2) Fix the baffle assembly with eight mounting bolts. a When sticking each sheet, see the following figure.

1) Stick sheets (25) to (28) on baffle (24), and install the baffle assembly at the bottom of the oil cooler. a When sticking each sheet, see the following figure.

50-74

WA1200-6

Engine and cooling system Removal and installation of radiator and hydraulic oil cooler assembly

3) Stick sheets (34) and (35) on baffle (33), and 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. a When sticking each sheet, see the following figure.

5) Stick sheets (37) and (38) on baffle (36), and 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. a When sticking each sheet, see the following figure.

WA1200-6

50-75

Engine and cooling system Removal and installation of radiator and hydraulic oil cooler assembly

4. Side face of fan guard (1) 1) Stick sheet (41) on baffle (40), and install the baffle assembly (LH) to the top of the left side face of rear oil cooler (39). 2) Fix the baffle assembly with two mounting bolts. 3) Stick sheet (43) on baffle (42), and install the baffle assembly (RH) to the top of the right side face of rear oil cooler (39). 4) Fix the baffle assembly with two mounting bolts. 5) Install baffle (LH) (44) on the left side face of the rear oil cooler. 6) Fix the baffle assembly with five mounting bolts. 7) Install baffle (RH) (45) on the right side face of the rear oil cooler. a When installing, apply the baffle rubber to the sheet on the radiator guard side. (See details of part P in the figure.) 8) Fix the baffle assembly with five mounting bolts. a Prefix "R50-36-" to the number in the following figure to know the number shown in the kit number list.

9) Install baffle (L.H) (47) to the top of the left side face of front oil cooler (46). 10)Fix the baffle assembly with five mounting bolts. 11)Install baffle (L.H) (48) to the bottom of the left side face of front oil cooler (46). 12)Fix the baffle assembly with three mounting bolts. 13)Stick sheet (50) on baffle (L.H) (49), and install the baffle assembly (L.H) to the center of the left side face of front oil cooler (46). a Do not peel the release paper in the range marked by an asterisk (*) on the sheet adhesive surface. 14)Fix the baffle assembly with two mounting bolts. 15)Install baffle (R.H) (51) to the top of the right side face of front oil cooler (46). 16)Fix the baffle assembly with five mounting bolts. 17)Install baffle (R.H) (52) to the bottom of the right side face of front oil cooler (46). 18)Fix the baffle assembly with three mounting bolts.

50-76

WA1200-6

Engine and cooling system Removal and installation of radiator and hydraulic oil cooler assembly

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 adhesive surface.

4) Stick sheets (69) and (70) on plate (68). a When sticking each sheet, see the following figure.

5. Bottom of oil cooler (2) 1) Install brackets (55) at the bottom of the rear oil cooler. (Four places)

2) Stick sheets (57) and (61) on baffle (L.H) (56). a When sticking each sheet, see the following figure.

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 assembly and plate, see the following figure.

3) Stick sheets (63) and (67) on baffle (R.H) (62). a When sticking each sheet, see the following figure. WA1200-6 50-77

Engine and cooling system Removal and installation of radiator and hydraulic oil cooler assembly

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 positions 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]

Radiator guard mounting bolts: 490 to 608 Nm {50 to 62 kgm}

[*2]

Hose insertion part: Gasket sealant (Three Bond 1208E) a Turn the hose clamp 180 degrees when installing it. [*3]
3

Radiator support mounting bolts: 490 to 608 Nm {50 to 62 kgm} Radiator and hydraulic oil cooler mounting bolt: 490 to 608 Nm {50 to 62 kgm}

[*4]

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

Engine and cooling system Removal and installation of engine assembly

Removal and installation of engine assembly

Special tools
Symbol

50-79

50-79
Necessity Q'ty New/redesign Sketch

7. Disconnect hoses (7)and (8). 8. Remove brackets (9) and (10). 9. Loosen the hose clamps and remove HTC radiator inlet tube (11), LTC radiator outlet tube (12), HTC radiator inlet tube (13), and LTC radiator inlet tube (8). [*2]

Part No.

Part name

1 SMT-890-5200 Lifting tool assembly 1-1 SMT-890-5210 q Frame Commercially q Single sling A 1-2 available Commercially q Quad sling 1-3 available

t 1 t 1 q 4 q 1

Removal
k

50-79

Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice".

1. Drain the engine coolant. 6 Coolant: 2. Drain the engine oil. 6 Engine oil:

approx. 540 l 10. Loosen hose clamps and remove tubes (14) and (15). [*3] approx. 260 l 11. Remove fan pulley cover (16). 12. Remove fan guard (17).

3. Remove the hood assembly, referring to "Removal and installation of hood assembly". 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

Engine and cooling system Removal and installation of engine assembly

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). 22. Disconnect hose (34). 23. Remove hose clamps (35) and disconnect hoses (36) and (37).

50-80

WA1200-6

Engine and cooling system Removal and installation of engine assembly

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

Engine and cooling system Removal and installation of engine assembly

31. Sling upper drive shaft (52), remove mounting bolts, and then remove the upper drive shaft. [* 5] a Remove the drive shaft after putting match marks on the coupling to indicate the mounting position. 4 Upper drive shaft: 115 kg

34. Slowly lift and remove engine assembly (55). a Lift by using tool A1 lifting tool assembly. a When removing the engine assembly, make sure that all the wiring harnesses and piping are disconnected. 4 Engine assembly: 8,600 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

Engine and cooling system Removal and installation of engine assembly

WA1200-6

50-83

Engine and cooling system Removal and installation of engine assembly

35. Disconnect the damper assembly according to the following procedure. 1) Sling cover assembly (56), remove mounting bolts (57), and then remove the cover assembly. [*8] 4 Cover assembly: 160 kg

Installation
q

50-84

perform installation in the reverse order to the removal.

[*1]

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 altered by 180 degrees. [*4] Adjust the belt tension. For details, see Testing and adjusting, "Testing and adjusting air conditioner compressor belt tension". [*5] 2) Remove two bolts (59) from the top of damper assembly (58). Sling the damper assembly by using eyebolts, remove mounting bolts (60), and then remove the damper assembly. [*9] 4 Damper assembly: 210 kg
3

Drive shaft mounting bolt: 157 to 196 Nm {16 to 20 kgm} Engine front mount mounting bolt: 824 to 1,030 Nm {84.0 to 105 kgm} Engine rear mount mounting bolt: 824 to 1,030 Nm {84.0 to 105 kgm}

[*6]

[*7]

[*8][*9] a Do not use grease other than ENS on the damper. If the grease other than ENS is used, it may cause unusual heat, premaure deterioration of the grease, and early deterioration of seal material. 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 referring to "Disassembly and assembly of damper" q When shaft (61) is removed, install it according to the following procedure.

50-84

WA1200-6

Engine and cooling system Removal and installation of engine assembly

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 desiccating 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 3 3

Cover mounting surface: Liquid gasket (LG-8) Cover assembly mounting bolt: 98 to 123 Nm {10 to 12.5 kgm} Damper assembly mounting bolt: 245 to 309 Nm {25 to 31.5 kgm}

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. 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

Engine and cooling system Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly

Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly 50-86
Removal 50-86 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the oil from the brake oil tank. 6 Brake oil tank: approx. 315 l 2. Remove covers (1) and (2). 4. Remove covers (3), (4), (5), (6), (7), and (8). 4 Cover (3): 30 kg 4 Cover (8): 35 kg

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

Engine and cooling system Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly

9. Remove U-bolts and disconnect tubes (16), (17), and (18).

Installation 50-87 perform installation in the reverse order to the removal.

[*1] 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: 550 kg

Refilling with oil (brake oil tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Refilling with oil (transmission) 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

50-87

Engine and cooling system Removal and installation of water-cooled torque converter and transmission oil cooler assembly

Removal and installation of water-cooled torque converter and transmission oil cooler assembly 50-8
Removal 50-8 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the engine coolant. 6 Coolant: 5. Sling the torque converter and transmission oil cooler assembly (8) at its right and left parts, remove mounting bolts (7), and then remove torque converter and transmission oil cooler assembly while moving them toward the front. [*1] 4 Torque convertor and transmission oil cooler assembly: 285 kg

approx. 540 l

2. Sling screens (1) and (2), and remove them.

Installation 3. Disconnect water hoses (3) and (4). 4. Remove oil tubes (5), (6), and (7). [*1]
3 q

50-8

perform installation in the reverse order to the removal. Torque converter and transmission oil cooler mounting bolt: 157 to 196 Nm {16 to 20 kgm}

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. Refilling of oil (transmission) 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.

50-88

WA1200-6

Engine and cooling system Removal and installation of damper assembly

Removal and installation of damper assembly

Special tools
Sym bol

50-89

50-89
Necessity Q'ty New/redesign Sketch

Part No.

Part name

6. Sling cover assembly (4), remove mounting bolts (5), and remove the assembly. [*2] a Using tool B5 to lower the assembly. 4 Cover assembly: 160 kg

B 5 SMT-890-5010 Lifting tool

t 1

Removal 50-89 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 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). 4. Disconnect hose (2).

5. Sling drive shaft (3) and remove bolts on the damper side. [*1] 4 Upper drive shaft: 115 kg

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: 210 kg

WA1200-6

50-89

Engine and cooling system Removal and installation of damper assembly

Installation
q

50-90

Perform installation in the reverse order to removal. 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

[*3] Use tool B5 to install the damper assembly. 3 Damper assembly mounting bolt: 245 to 309 Nm {25 to 31.5 kgm}

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: Liquid gasket (LG-8) 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 lubricating) 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". 2 Grease reservoir "f": 100 g (ENS grease) q ENS grease part No.: 427-12-11871 (2 kg can)

50-90

WA1200-6

Engine and cooling system Disassembly and assembly of damper

Disassembly and assembly of damper

Special tools
Symbol Necessity Q'ty New/redesign Sketch

50-91

50-91

Part No.

Part name

1 SMT-890-1830 Spacer 2 SMT-890-1710 Sleeve B 3 SMT-890-1810 Push tool 790-201-2100 Push tool 4 790-201-2390 q Plate

t t t t t

1 1 1 1 1

Q Q Q

Disassembly

50-91 7) Using tool [1], remove two bearings (10) and spacer (11) from damper cover (1). a Do not reuse the removed bearing.

1. Damper cover 1) Remove cage (4). 2) Remove seal (2) from cage (4). a Do not reuse the removed oil seal. 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

Engine and cooling system Disassembly and assembly of damper

2. Damper 1) Remove 20 mounting bolts (12), and remove flange (13) using forcing screws.

3) Remove inner body (18) from outer body (17).

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

Engine and cooling system Disassembly and assembly of damper

Assembly

50-93

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.

1. Damper 1) Install plate (23) and washers (22) to inner body (18), and tighten mounting bolt (21). 2 Contact surfaces on inner body and plate: Liquid gasket (LG-8) 3 Mounting bolt: 98 to 123 Nm {10 to 12.5 kgm}

2) Install flange (20) to outer body (17), and tighten 20 mounting bolts (19). 2 Contact surfaces on outer body and flange: Liquid gasket (LG-8) 3 Mounting bolt 245 to 309 Nm {25 to 31.5 kgm}

WA1200-6

50-93

Engine and cooling system Disassembly and assembly of damper

3) Reverse outer body (17), and install inner body (18).

5) Install flange (13), and tighten 20 mounting bolts (12). 2 Contact surfaces on outer body and flange: Liquid gasket (LG-8) 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 (2kg can) a Install large and small rubbers as shown in the figure, viewing from the flywheel side. a After installing the rubbers, check that mark "a" (at four portions on the periphery) of the outer body matches the lever end of the inner body.

2. Damper cover Bearing 1) Set tool B1 on the press bench, and then place damper cover (1) on tool B1. a Take care not to set the damper cover tilted.

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Engine and cooling system Disassembly and assembly of damper

2) Apply adhesive on the periphery of bearing (10A), and press fit the bearing into the press-fit part of damper cover (1) using installation tool B2. a Be careful to install shields (a) and (b) of the bearing facing toward the seal.(See the following figure.) a Apply grease to the open side (opposite of the shield side) of the bearing. 2 Outside periphery of bearing: Adhesive (LOCTITE 601) 2 Open sides "X" and "Y" of bearing: ENS grease (150 g /bearing)

Cover 1) Reverse cover (1), set oil seal (6) to the press fit part, and press fit the oil seal by using installation tool B3. 2 Outer periphery of oil seal: Adhesive (LOCTITE 601) a Degrease the inner periphery of cover (1) and the outer periphery of oil seal (6). a Take care that the oil seal does not slant. 2) Apply grease to clearance "S" between oil seal (6) and bearing (10A). a Also apply grease to the oil seal lip part. 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 that inner diameter of the spacer matches that of the bearing. a Press fit bearings one by one. a After pressing fit the bearing, check that the clearance "a" is within the standard value by using the feeler gauge. q Standard clearance "a": 0.1 to 0.6 mm

3) Install tool B2 at the bottom of bearing (10B), and clean and degrease the inner peripheries of bearings (10A) and (10B) and the outer periphery of shaft (3). 4) Apply adhesive to the inner peripheries of bearings (10A) and (10B). 2 Inner peripheries of bearings (10A) 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.

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Engine and cooling system Disassembly and assembly of damper

8) Reverse cover and shaft assembly (1), and install snap ring (5). a Securely install the snap ring in the groove.

11)Press fit oil seal (2), and apply grease to clearance "T". a Also apply grease to the oil seal lip. 2 Clearance "T" between oil seal and bearing: ENS grease (100 g) q ENS grease part No.: 427-12-11871 (2 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 standard value by using the gauge. q Standard value of level difference "b": 5.05 to 6.65 10)Press fit oil seal (2) to cage (4) using installation tool B4. 2 Outer periphery of oil seal: Adhesive (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.

12)Install cage (4) and oil seal (2) to cover (1). 2 Mating faces U on cage (4) and cover (1): Liquid gasket (LG-8) 3 Bolt: 98 to 123 Nm {10 to 12.5 kgm}

13)Install breathers (7) and (8), and plug (9). 3 Breather (7): 50-96 WA1200-6

Engine and cooling system Disassembly and assembly of damper

3 3 3

4.9 to 9.8 Nm {0.5 to 1.0 kgm} Elbow (8): 4.9 to 9.8 Nm {0.5 to 1.0 kgm} Bolt (Tube mounting bolt): 98 to 123 Nm {10 to 12.5 kgm} Fitting (22): 2.9 to 4.9 Nm {0.3 to 0.5 kgm}

3. Charging bearing chamber with grease a Be sure to charge it with the specified amount of grease. a Before charging the bearing chamber with ENS grease, make sure that other greases are completely removed from it. Never mix ENS grease with other greases. Use a grease gun exclusive to the ENS grease. 1) Charge grease reservoir "d" between bearings 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 lubricating) 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. 2 Grease reservoir "f": ENS grease (100g) q ENS grease part No.: 427-12-11871 (2 kg can)

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Engine and cooling system Removal and installation of bumper and fuel tank assembly

Removal and installation of bumper and fuel tank assembly

Removal k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain fuel from the tank. 6 Fuel: Approx. 5,100 l(specified amount) 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). 8. Lift and remove steps (9) and (10). 9. Remove step covers (11), (12), (13), and (14). 10. Disconnect hoses (15) and (16).

50-98
50-98

11. Disconnect fuel level sensor wiring harness connector R05 (18).

12. Disconnect wiring harness connector GR1 (19).

6. Lift and remove handrails (6) and (7). 7. Remove step (8).

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Engine and cooling system Removal and installation of bumper and fuel tank assembly

13. Set a support stand [1] under the bumper. 14. Sling the right and left sides of the bumper with nylon slings, remove mounting bolts (20), and then remove the bumper and fuel tank assembly (21). [*1] a To avoid damage to the nylon slings, use cushioning material at bumper corners. 4 Bumper and fuel tank assembly: 6,950 kg

Installation
q

50-9

perform installation in the reverse order to the removal.

[*1]

Fuel tank mounting bolt: 1,127 to 1,911 Nm {115 to 195 kgm}

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.

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50-99

Engine and cooling system Removal and installation of hood assembly

Removal and installation of hood assembly

Removal 50-10 k Before performing removal, be sure to implement "2. Preparatory work" in "00 Safety notice". 1. Sling and remove handrail (1) and right and left handrails (2). 2. Sling and remove two exhaust pipes (3).
4

50-10

50-10 Installation q Perform installation in the reverse order to removal. [*1] Alignment procedure for installing exhaust pipe q When installing the muffler stack, align the centers of the muffler stack and the muffler exhaust port according to the following procedure. 1. Before installing the muffler stack, prepare a pattern [1] of the following dimensions. A (outside diameter): f392 mm B (inside diameter): f162 mm

[*1] Exhaust pipe: 30 kg x 2 pipes

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]

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Engine and cooling system 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 pattern.

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} Mounting nut of bracket (6): 490 to 608 Nm {50 to 62 kgm}

[*3]

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50-101

Engine and cooling system Disassembly and assembly procedures for MESABI oil cooler

Disassembly and assembly procedures for MESABI oil cooler

q

50-102

Outline 1. Name of each part of oil cooler assembly

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Engine and cooling system Disassembly and assembly procedures for MESABI oil cooler

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Engine and cooling system Disassembly and assembly procedures for MESABI oil cooler

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
Device Symbol A B C D E F Part No. 793-803-1110 793-803-1130 793-803-1120 793-301-1600 793-803-1150 793-803-1160 Part name Support instrument Tube instrument Breaker tool Air leak checker Flange Flange Q'ty 1 1 1 1 1 1 Nature of work, remarks Removal and installation of core Air leak check on the cores

Disassembly and assembly of oil cooler

4. Spare parts list

No. 1 2 3 4 5 6 Part No. LM35780 LM63377 LM33567 LM33083-107 LM123-10-4200 LM48622 Part name Rubber seal Copper washer Tube retainer Air baffle ITS tube Tube support Q'ty 1,824 2,736 912 2 912 912 Remarks

Note: Blind plugs are not available as service parts because they cannot be used due to high operation pressure.

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

Disassembly and assembly of MESABI oil cooler

Preparation work 50-105 1) Clean the oil cooler assembly by using a hot water cleaner. Turn around the assembly and clean the other side. a Use a detergent. a Pressure: Max. 1,200 PSI, 8.3 MPa {84.4 kg/cm2} a Water temperature: Max. 180 deg. F {82 C} a Do not use steam.

50-105

3) Place the oil cooler assembly on a level work stand. a Place a corrugated or wooden board on the oil cooler so that you can place objects on it. a If it is necessary for a worker to climb the assembly during work, place a durable wooden plate on the assembly to protect the tubes and fins against excessive stress.

2) When cleaning is finished, remove excessive water by using an air blower.

50-105 Disassembly 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.

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

2. Removal of tubes a First remove the tubes from the top cores. 1) Use pliers to pinch the tube, and then remove the retainer clip.

4) For easy tube removal, apply lubricating oil to the top seal, bottom seal, and tube support.

2) Clean the tubes by using air, and wipe off the stain.

5) The tube and rubber seal may stick together to make the removal difficult. In this case, remove the tube while wobbling it by using breaker tool C.

3) Reposition the copper washer toward the fin (bottom side) so that it does not generate resistance when removing the tube.

6) Remove the tube from the bottom seal by using tube instrument B. 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)

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

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 portion 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 damaged or the tube from being kinked.

a After performing steps 6) and 7), check that the tube support is disengaged.

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

10)Under the original tube installation condition, the tools cannot work well in the ribbed locations 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.

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

Assembly

50-109

a Clean the surface of each part and the inner surface of holes, etc. by using a factory rag and air. 1. Installation of tube 1) Install the rubber seal by hand. a If the rubber seal is hard due to low temperatures, warm it in hot water before installation. 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.

a If you insert the rubber seal too much, the rubber seal is deformed in a concave shape, reducing the inner diameter. The reduced inner diameter generates excessive stress when a tube is inserted, damaging the seal. Install the rubber seal carefully.

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.

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

4) Check that copper washers are placed at both ends of the tube. q Top end: 2 pieces q Bottom end: 1 piece a When the assembly is installed on the machine and is in vertical position, place the copper washer at the bottom end immediately before inserting the tube into the bottom seal to prevent the copper washer from falling. 5) Align the top end of the tube with the hole in the rubber seal, and then insert the tube.

8) Insert the tube by hand until the meshing portion of the tube support comes to the tube. a If you attempt to insert the tube by using a tool though the tube is not aligned with the hole in the rubber seal, the rubber seal is pressed, resulting in the same condition as that caused by excessive insertion where the rubber seal may be damaged.

6) Check the position of the tube support.

9) Using tube instrument B and support instrument A, insert the tube until the copper 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 little by hand.

10)Install the retainer clip between the copper washers by using pliers.

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

a Adjust the retainer clip tab position to prevent air leakage (for prevention of impaired cooling performance). a If you moved the air buffer to disassemble the assembly partially, be sure to return it to the original position.

13)Because there are ribs in corner areas, working in those areas is very difficult. Pay sufficient attention when positioning and inserting the tube into the hole. a The work must be done by two people in 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.

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Engine and cooling system Disassembly and assembly of MESABI oil cooler

2. Install the support bar. After installing tubes on the front side, install the support bar by using the matchmark that you put in the disassembly procedure.

3. Apply and hold air pressure. a Air pressure: 0.88 to 1.03 MPa {9.0 to 10.5 kg/cm2} 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. 50-1 2 Pressurization test 1. Install flange E to the outlet port of the oil cooler.

4. Disconnect the air source pressure hose. 5. Check that the air pressure does not decrease in one hour. a If a decrease in air pressure is found, locate the air leakage audibly or by using soap water 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.

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Power train Removal and installation of torque converter and transmission assembly

Power train

Removal and installation of torque converter and transmission assembly

Removal 50-1 3 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work", and "8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit" in "00 Safety notice". k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. 1. Drain the hydraulic oil. 6 Hydraulic oil: 2. Drain the transmission oil. 6 Transmission oil: 8. Lift and remove drive shaft guards (3) and (4). 9. Lift and remove underguards (5) and (6).

50-1 3
50-1 3

approx. 1,125 l

approx. 350 l 10. Disconnect wiring harness connectors R31(7a) and R32(7b).

3. Remove the hood assembly, referring to "Removal and installation of hood assembly". 4. Remove the bulkhead assembly, referring to "Removal and installation of bulkhead assembly". 5. Remove the operators cab assembly. For details, see "Removal and installation of operators 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.

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Power train Removal and installation of torque converter and transmission assembly

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). 15. Disconnect suction tube (17).

16. Disconnect hoses (18) and (19). 20. Disconnect hoses (31) and (32).

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Power train Removal and installation of torque converter and transmission assembly

21. Remove hose clamps (33) and disconnect nine hoses (34).

27. Disconnect hoses (50), (51), (52), and then lift and remove lower emergency steering pump assembly (53). a In the same way as the above procedure, remove the upper emergency steering pump assembly.

22. Remove hose clamp (35) and disconnect hoses (36) and (37). 23. Disconnect hoses (38) and (39). 28. Disconnect hoses (101), (102), (103), and (104).

24. Disconnect wiring harness connector MT3 (41). 25. Disconnect hoses (42), (43), (44), and (45). 26. Remove valve assembly (46). [*2] 29. Disconnect tubes (105), (106), (107), and (108).

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Power train Removal and installation of torque converter and transmission assembly

30. Disconnect hoses (54) and (55) and remove transmission oil filler (56).

36. Remove hoses (67) and (68). 37. Disconnect tubes (69), (70), (71), and (72). 38. Remove clamp (73) and remove hose (74). 39. Disconnect hose (75). 40. Remove suction tube (76).

31. Disconnect hoses (57), (58), and (59).

41. Disconnect hoses (91), (92), (93), and (94). 42. Remove hoes and remove suction tubes (95) and (96). 43. Disconnect hoses (97), (98), and (99).

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). 35. Disconnect hose (66).

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Power train Removal and installation of torque converter and transmission assembly

44. Remove the wiring harness clamps and disconnect wiring harness connectors TM1 (78) and TM2 (79).

47. Sling upper drive shaft (83), remove mounting bolts, and then remove the upper drive shaft. [*3] a Remove the drive shaft after putting match marks on the coupling to indicate the mounting position. 4 Upper drive shaft: 115 kg 48. Sling rear drive shaft (84), remove mounting bolts, and then remove the rear drive shaft. [*4] a Remove the drive shaft after putting match marks on the coupling to indicate the mounting 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] a Remove the drive shaft after putting match marks on the coupling to indicate the mounting 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]

46. Disconnect hoses (81) and (82).

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Power train Removal and installation of torque converter and transmission assembly

52. Slowly lift and remove transmission assembly (86). a When removing the transmission assembly, make sure that all the piping and wiring harnesses are disconnected. 4 Transmission assembly: 6,550 kg a When lifting the transmission assembly, use wire ropes longer than 2.0 m on the transmission (a).Adjust the length of the wire ropes on the torque converter (b) to lift the transmission in a horizontal attitude.

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Power train Removal and installation of torque converter and transmission assembly

Installation q perform installation in the reverse order to the removal. [*1] 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
Connection Hose size/ Tube size f8 Nut type D 1/2 D 5/8 Block joint Thread size M16 x 1.5 M22 x 1.5 M24 x 1.5 Receiver tank M16 x 1.5 Other than receiver tank M16x1.5 Tightening torque Nm {kgm} 118 to 147 {12 to 15} 196 to 245 {20 to 25} 294 to 343 {30 to 35} 39 to 69 {4.0 to 7.0} 78 to 118 {8.0 to 12} Used at COND1 out COND2 out rec to unit in COND1 in COND2 in Unit out Receiver tank Compressor A/C unit
2

50-1 9

Filling of refrigerant (air conditioner gas: R134a) Fill the air conditioner circuit with the refrigerant (R134a). a Filling quantity: 1,400 100 g a If gas leakage occurs after tightening the flare nut, clean the flare portion, apply ND-OIL8, and then tighten it to the specified torque shown in the above table. [*2]
3

[*7]

3 q q

Front mount bracket mounting bolt: Bolt (89): 785 to 980 Nm {80.0 to 100 kgm} Bolt (90): 785 to 980 Nm {80.0 to 100 kgm}

Refilling with oil (transmission) 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. Refilling with oil (hydraulic tank) Refill the hydraulic tank with 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. Precautions for filling air conditioner with refrigerant See "8. Precautions for connecting hoses and tubes, and filling of refrigerant in the air conditioner circuit" in "00 Safety notice". Air bleeding Bleed air from the piston pump and work equipment hydraulic circuit. For details, see "Bleeding air from piston pump" and "Bleeding air from work equipment circuit and steering circuit".

Valve assembly mounting bolt: 44.1 to 53.9 Nm {4.5 to 5.5 kgm} Upper drive shaft mounting bolt: 157 to 196 Nm {16 to 20 kgm} Rear drive shaft mounting bolt: 343 to 427 Nm {35 to 43.5 kgm}
q

[*3]

[*4]

[*5]

Center drive shaft mounting bolt: 343 to 427 Nm {35 to 43.5 kgm} Rear mount mounting bolt: 824 to 1,030 Nm {84 to 105 kgm}

[*6]

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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

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Power train Disconnection and connection of transmission assembly and torque converter assembly

Replacing consumables a Replace all consumable parts (O-rings, seal rings, etc.) used with new ones when re-connecting the transmission and torque converter assemblies. List of consumables to be replaced at service KIT No.: 42C-15-05060, 42C-15-05270 For details of KIT No., see the end of this section. 50-121 Disconnection 1. Preparation work Support the torque converter assembly with blocks, etc. so that it is kept level. k Securely hold the bottom of the transmission case so that the transmission assembly does not fall down when the torque converter assembly is disconnected. 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). 3) Remove six mounting bolts to remove drain tube (4). 4) Remove six mounting bolts to remove drain tube (5). 5) Remove eight mounting bolts to remove lubrication tube (7). 6) Remove two mounting bolts to remove lubrication tube (6a). 4. Lubrication hose Removes lubrication tubes 6a and 6b. a Remove hose clamp as well.

50-121 5. Disconnecting torque converter assembly 1) Sling torque converter assembly (9), and remove 25 mounting bolts. 2) Disconnect torque converter assembly (9) from transmission assembly (10). a Horizontally pull out the torque converter until the input shaft of the transmission is separated completely. 4 Torque converter assembly: Approx. 1,500 kg 4 Transmission assembly: Approx. 3,800 kg a For procedures for disassembling the torque converter assembly, see "Disassembly and assembly of torque converter". a For procedures for disassembling the transmission, see "Disassembly and assembly of transmission".

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Power train Disconnection and connection of transmission assembly and torque converter assembly

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. 4) Fit the O-ring, and install drain tube (4) by using six bolts. 5) Fit the O-ring, and install drain tube (3) by 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.

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Power train Disconnection and connection of transmission assembly and torque converter assembly

Service kit parts list KIT No.: 42C-15-05060 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K05) (Transmission case)
Index 7 8 9 10 11 12 21 Part No. 19M-15-11440 07000-72125 07000-73040 07000-73048 07000-72075 07000-72065 07000-72125 Part name O-RING O-RING O-RING O-RING O-RING O-RING O-RING Q'ty 1 2 1 1 1 1 2

Service kit parts list KIT No.: 42C-15-05270 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K04) (Transmission case)
Index 22 23 24 26 Part No. 07000-73032 07000-73050 07000-73040 07000-73025 Part name O-RING O-RING O-RING O-RING Q'ty 7 10 4 1

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Power train Disconnection and connection of transmission assembly and torque converter assembly

Service kit parts list KIT No.: 42C-15-05270 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K04) (Transmission piping)
Index 3 9 12 15 18 22 40 Part No. 07005-02012 07005-02012 07005-02012 07005-02012 07005-02012 07000-73048 07000-73050 Part name GASFET GASFET GASFET GASFET GASFET O-RING O-RING Q'ty 4 4 4 6 4 1 1

Service kit parts list KIT No.: 42C-15-05270 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K04) (Transmission valve seat)
Index 6 7 8 9 Part No. 07000-72018 07000-72021 07000-73032 07000-73050 Part name O-RING O-RING O-RING O-RING Q'ty 6 7 2 1

50-124

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Power train Disconnection and connection of transmission assembly and torque converter assembly

Service kit parts list KIT No.: 42C-15-05270 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K04) (Transmission control valve filter)
Index Part No. 7 07000-73028 9 07000-73022 15 07000-73035 Part name O-RING O-RING O-RING Q'ty 2 2 3

Service kit parts list KIT No.: 42C-15-05270 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K04) (Transmission flange cover)
Index Part No. 25 02896-61015 27 07002-62034 Part name O-RING O-RING Q'ty 1 2

WA1200-6

50-125

Power train Disconnection and connection of transmission assembly and torque converter assembly

Service kit parts list KIT No.: 42C-15-05270 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K04) (Transmission wiring and piping)
Index Part No. 9 07000-72105 10 07000-72090 Part name O-RING O-RING Q'ty 3 3

Service kit parts list KIT No.: 42C-15-05270 (Torque converter and transmission connection service kit) Fig.No.: Y0 Y99-0000002 (K04) (Transmission wiring and piping)
Index 4 6 7 14 22 Part No. 07000-73025 07002-62034 02896-61015 07000-73025 07000-73048 Part name O-RING O-RING O-RING O-RING O-RING Q'ty 1 1 1 1 2

50-126

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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 and connection of torque converter assembly, PTO and transfer assembly

Disconnection

50-128

1. Breather and breather hose 1) Remove breather hose (1). 2) Remove two mounting bolts, and remove breather (2) and the block as a unit. 3) Remove elbow (3). 2. Lubrication tube and block 1) Remove lubrication tubes (21) and (22). a Remove the tube clamps also. 2) Remove four mounting bolts and flange, and remove lubrication tube (6). a Remove the tube clamp also. 3) Remove four mounting bolts to remove block (7). 4) Remove lubrication tube (8). 5) Remove three joints and remove lubrication tube (9). 6) Remove two joints from each lubrication tube, and remove lubrication tubes (10), (11), (12) and (13). 7) Remove two mounting bolts, and remove block (14) and bracket (15). 8) Remove three mounting bolts to remove block (16). 3. Main relief valve and torque converter relief valve assembly Remove seven mounting bolts, and remove main relief valve and torque converter relief valve assembly (17). 4. Torque converter regulator valve assembly 1) Remove four mounting bolts to remove block (18). 2) Remove sleeve (19). 3) Remove four mounting bolts, and remove cover (20) and block (21). 4) Remove four mounting bolts, and remove torque converter regulator valve assembly (22). 5) Remove valve block assembly (23).

5. Modulation clutch ECMV assembly 1) Remove three mounting bolts to remove cover (24). 2) Remove four mounting bolts, and remove modulation clutch ECMV assembly (25). 6. Speed sensor Loosen the locknut and remove speed sensor (26). 7. Modulation clutch assembly Remove ten mounting bolts, and remove modulation clutch assembly (27). a The hexagonal socket bolt is not a mounting bolt. Do not remove it. a Using forcing screws (12 mm), pull out the assembly. a Since the inner and outer races of the roller bearing are separated, pull it out horizontally so that it is not pried. 4 Modulation clutch assembly: 220 kg a For procedures for disassembling the modulation clutch, see "Disassembly and assembly of modulation clutch". 8. Torque converter assembly, and PTO and transfer assembly 1) Remove 19 mounting bolts, and disconnect torque converter assembly (28) from PTO and transfer assembly (29). 4 Torque converter assembly: 430 kg 4 PTO and transfer assembly: 800 kg a For procedures for disassembling the torque converter, see "Disassembly and assembly of torque converter". a For procedures for disassembling the PTO and transfer, see "Disassembly and assembly of PTO and transfer". 2) Remove coupling (30) from torque converter assembly (28).

50-128

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Power train Disconnection and connection of torque converter assembly, PTO and transfer assembly

Connection

50-129

1. Torque converter assembly, and PTO and transfer assembly 1) Install coupling (30) to torque converter assembly (28). 2) Fit the O-rings to the joint portion of torque converter assembly (28) and PTO and transfer assembly (29). 2 O-ring: Grease (G2-LI) 3) Install torque converter assembly (28) to PTO and transfer assembly (29) with 19 bolts. a Since the inner and outer races of the taper roller bearing are combined together, drop transmission oil (TO30 or TO10) about 6 cc to the roller sliding surface. 4 Torque converter assembly: 430 kg 4 PTO and transfer assembly: 800 kg 2. Modulation clutch assembly Fit the O-ring and install modulation clutch assembly (27) with ten bolts. 2 O-ring: Grease (G2-LI) a Since the inner and outer races of the roller bearing are combined together, drop transmission oil (TO30 or TO10) about 6 cc to the roller sliding surface, and insert it horizontally so that it is not pried. 4 Modulation clutch assembly: 220 kg 3. Speed sensor Install speed sensor (26) and secure it with the lock nut. 2 Threaded portion of sensor: Liquid gasket (LG-5) a Apply the speed sensor end lightly to the gear tooth tip located inside of the modulation clutch, return the sensor from that position 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}

4. Modulation clutch ECMV assembly 1) Fit the O-ring and install modulation clutch ECMV assembly (25) with four bolts. 3 Mounting bolt: 27.4 to 34.3 Nm {2.8 to 3.5 kgm} 2) Install cover (24) with three bolts. 5. Torque converter regulator valve assembly 1) Fit the O-ring and install valve block assembly (23) with four bolts. 3 Mounting bolt: 44.1 to 53.9 Nm {4.5 to 5.5 kgm} 2) Fit the O-ring and install torque converter regulator valve assembly (22) with four bolts. 3 Mounting bolt: 44.1 to 53.9 Nm {4.5 to 5.5 kgm} 3) Fit the O-ring and install block (21) and cover (20) with four bolts. 4) Fit the O-ring and install sleeve (19). 2 O-ring: Grease (G2-LI) 5) Fit the O-ring and install block (18) with four bolts. 6. Main relief valve and torque converter relief valve assembly Fit the gasket and install main relief valve and torque converter relief valve assembly (17) with nine bolts. 3 Mounting bolt: 58.8 to 73.5 Nm {6.0 to 7.5 kgm} 7. Lubrication tube and block 1) Fit the O-ring and install block (16) with three bolts. 2) Install bracket (15) and block (14) with two bolts.

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Power train Disconnection and connection of torque converter assembly, PTO and transfer assembly

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

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Power train Disassembly and assembly of torque converter

Disassembly and assembly of torque converter

50-131

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50-131

Power train Disassembly and assembly of torque converter

a Replace all consumable parts (O-rings, seal rings, etc.) used in the torque converter and modulation clutch with new ones when re-assembling the torque converter and modulation clutch. a For details of KIT No., see the end of this section. KIT No.: 42C-13-05280 and 42C-13-05290 50-132 Disassembly 1. Preparation work 1) Set the torque converter assembly vertically with the input shaft up. a Adjust the height of the assembly using blocks to allow removal of the mounting bolts from under the case. 2. Case Remove 13 mounting bolts to remove the torque converter from case (1). a Attach the eyebolt (12 mm) to the end of the input shaft, lift the torque converter vertically with all parts in the case assembled. a Place the removed torque converter on a work stand with the input shaft up. 3. Input shaft 1) Remove 20 mounting bolts to remove shaft (2). 2) Remove the inner race of taper roller bearing (3) from shaft (2). a Use a bearing puller to pull out. 4. Case and turbine assembly 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).

4) Remove turbine (9). a Use forcing screws (10 mm) to pull out. 5) Remove ball bearing (10) from case (11). a Since the bearing has a snap ring, take care not to push the bearing from the snap ring side when removing the bearing with a press. 5. Stator 1) Remove snap ring (12), then remove stator (13). 2) Remove spacer (14). 6. Pump assembly 1) Remove pump assembly (15). a Since the inner and outer races of the roller bearing are separated, lift the assembly straight up, taking care not to pry the races. 2) Remove 16 mounting bolts to remove retainer (16) and guide (17) from pump (18). 3) Remove the outer race of roller bearing (19) from guide (17). a Use a press to pull out. 4) Remove drain plug (20) from pump (18). 7. Shaft 1) Remove four mounting bolts to remove plate (21) from shaft (22). 2) Remove seal ring (23) from shaft (22). 3) Remove the inner race of roller bearing (19) from shaft (22). a Use a bearing puller to pull out. 4) Remove sleeve (24) from shaft (22).

50-132

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Power train Disassembly and assembly of torque converter

2

Assembly 50-13 1. Shaft 1) Install sleeve (24) to shaft (22). a Install the sleeve by expansion fit. 2) Press fit the inner race of roller bearing (19) to shaft (22). a Using a press, press fit the bearing until the end face of inner race comes in contact with the stepped part of the shaft. 3) Install plate (21) to shaft (22) with four bolts. 4) Install seal ring (23) to shaft (22). 2 Seal ring: Grease (G2-LI) 2. Pump assembly 1) Install drain plug (20) to pump (18). 3 Drain plug: 9.8 to 12.7 Nm {1.0 to 1.3 kgm} 2) Press fit the outer race of roller bearing (19) into guide (17). a Apply bearing compound to four places on the bearing outer periphery. Wipe off any extra compound to prevent it from entering into the bearing.

Mounting bolt threaded section: Adhesive (LT-2) 3 Mounting bolt: 59 to 74 Nm {6.0 to 7.5 kgm} 4) Install pump assembly (15) to shaft (22). a Since the inner and outer races of the roller bearing are combined together, lower the assembly straight down, taking care not to pry the races. 3. Stator 1) Install spacer (14). 2) Install stator (13) and secure it with snap ring (12). 4. Case and turbine assembly 1) Install ball bearing (10) to case (11). a Using a press, press fit the bearing until the snap ring comes in contact with the stepped part of the case. a After press fitting the bearing, drop transmission oil (T030 or T010) about 6 cc to the sliding portion and rotate 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: Adhesive (LT-2) 3 Mounting bolt: 49 to 59 Nm {5 to 6 kgm}

a Using a press, press fit the bearing until the end face of outer race comes in contact with the stepped part of the guide. 3) Install guide (17) and retainer (16) to pump (18) with 16 bolts.

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Power train Disassembly and assembly of torque converter

5. Input shaft 1) Install the inner race of taper roller bearing (3) to shaft (2). a Using a press, press fit the bearing until the end face of inner race comes in contact with the stepped part of the shaft. 2) Install shaft (2) with 20 bolts. 2 Mounting bolt threaded section: 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. 2 Mounting bolt threaded section: Adhesive (LT-2) 3 Mounting bolt: 245 to 309 Nm {25.0 to 31.5 kgm}

50-134

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Power train Disassembly and assembly of torque converter

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (modulating clutch) (case)
Index 6 7 9 10 16 17 18 23 Part No. 07000-72115 07000-72018 07002-61423 07000-75160 07000-75375 07000-72115 07000-75355 07002-61423 Part name O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING Q'ty 1 4 3 1 1 1 1 2

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (modulating clutch) (clutch)
Index Part No. 5 124-960-2180 9 714-10-19220 Part name RING RING SEAL Q'ty 2 1

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50-135

Power train Disassembly and assembly of torque converter

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (modulating clutch) (ECMV)
Index 2* 5* 5* 5* 5* 5* Part No. 561-15-55630 07000-73025 07000-73028 07000-73035 07000-72018 07002-61023 Part name SHIM O-RING O-RING O-RING O-RING O-RING Q'ty 3 1 1 1 1 1

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (torque converter input transfer case)
Index 4 Part No. Part name 42C-13-15280 GASKET Q'ty 1

50-136

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Power train Disassembly and assembly of torque converter

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (torque converter input transfer gear)
Index 6 7 16 19 20 21 22 29 30 Part No. 42C-13-05010 07000-75385 42C-13-05020 07000-75425 07000-75200 07000-75085 07012-50110 07000-75270 07000-75230 Part name SHIM KIT O-RING SHIM KIT O-RING O-RING O-RING SEAL OIL O-RING O-RING Q'ty 1 2 1 1 1 1 1 3 1

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (torque converter input transfer gear)
Index 4 5 12 15 Part No. 42C-13-05030 07000-75210 42C-13-05040 07000-72130 Part name SHIM KIT O-RING SHIM KIT O-RING Q'ty 1 1 1 1

WA1200-6

50-137

Power train Disassembly and assembly of torque converter

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (torque converter input transfer piping)
Index 12 18 24 25 28 29 Part No. 07000-73028 07005-02012 07002-62434 02896-61015 07002-62434 02896-61015 Part name O-RING GASKET O-RING O-RING O-RING O-RING Q'ty 1 22 2 2 2 2

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (torque converter input transfer piping)
Index 9 10 20 Part No. 07002-62034 02896-61012 02896-61018 Part name O-RING O-RING O-RING Q'ty 2 2 2

50-138

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Power train Disassembly and assembly of torque converter

Service kit parts list KIT No.: 42C-13-05280 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K01) (torque converter input case)
Index 2 5 27 Part No. Part name 07000-72115 O-RING 19M-13-13340 O-RING 42C-13-22710 SEAL RING Q'ty 1 1 1

Service kit parts list KIT No.: 42C-13-05290 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K02) (torque converter valve)
Index 9 13 17 18 26 28 34 Part No. 07000-73038 07000-73042 07000-73048 07000-72014 42C-13-13110 07000-73048 07000-72018 Part name O-RING O-RING O-RING O-RING GASKET O-RING O-RING Q'ty 2 1 2 4 1 1 2

WA1200-6

50-139

Power train Disassembly and assembly of torque converter

Service kit parts list KIT No.: 42C-13-05290 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K02) (torque converter valve)
Index 3 6 12 15 Part No. 07000-73045 07000-72055 07000-72014 07002-61023 Part name O-RING O-RING O-RING O-RING Q'ty 2 3 1 1

Service kit parts list KIT No.: 42C-13-05290 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K02) (torque converter valve)
Index 7 12 13 Part No. 07000-73045 07000-72014 07002-61023 Part name O-RING O-RING O-RING Q'ty 2 1 1

50-140

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Power train Disassembly and assembly of torque converter

Service kit parts list KIT No.: 42C-13-05290 (torque converter installation service kit) Fig. No.: Y0 Y99-0000002 (K02) (torque converter valve)
Index 3 4 18 24 25 Part No. 07002-61023 07000-72055 07000-73045 6206-21-9460 42C-13-16220 Part name O-RING O-RING O-RING SHIM SHIM Q'ty 2 2 2 6 4

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50-141

Power train Disassembly and assembly of modulation clutch

Disassembly and assembly of modulation clutch

50-142

50-142

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Power train Disassembly and assembly of modulation clutch

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-143

Part No.

Part name

2 SMT-890-1230 Socket 4 SMT-890-1310 Wrench

t t

1 1

Q Q

5. Piston 1) Using tool C4, remove nut (24). a For tool C4, see the "Sketches of special tools". 2) Remove plate (25). 3) Remove seal ring (26) from plate (25). 4) Remove piston (27). a Push out the piston from the shaft side using forcing screw (12 mm). 6. Output drum Remove 12 mounting bolts to remove drum (28). a Push out the drum from the shaft side using forcing screw (12 mm). 7. Shaft 1) Remove seal rings (29) and (30) from shaft (31). 2) Remove two seal rings (32) from shaft (31). 3) Remove the inner race of roller bearing (33) from shaft (31). a Use a bearing puller to pull out.

Disassembly 50-143 1. Cage 1) Remove four mounting bolts to remove cage (1). a Using forcing screws (12 mm), pull out the cage. 2) Remove snap ring (2), then remove bushing (3) and ball (4) from cage (1). 2. Case 1) Remove snap ring (5). 2) Remove two mounting bolts to remove case (6). 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). a Use a press to pull out. 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 Disassembly and assembly of modulation clutch

50-14 Assembly 1. Shaft 1) Press fit the inner race of roller bearing (33) to shaft (31). a Using a press, press fit the bearing until the end face of inner race comes in contact with the stepped part of the shaft. 2) Install seal ring (32) to shaft (31). 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 drawing below.

3. Piston 1) Install piston (27). 2) Install seal ring (26) to plate (25). 2 Seal ring: Grease (G2-LI) a Install the seal ring as shown in the drawing below, paying attention to the installed direction of the seal ring.

2. Output drum Install drum (28) with 12 bolts. 2 Mounting bolt threaded portion: Adhesive (LT-2) 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

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: 313.8 to 392.3 Nm {32 to 40 kgm} 4. Discs and plates 1) Install damper (23) a Install the damper with its cork side facing the piston. 2) Install 19 discs (21) and 18 plates (22) alternately. 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

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Power train Disassembly and assembly of modulation clutch

5. Cover and input drum assembly 1) Using tool C2, install ball bearing (16) to cover (14) and secure it with snap ring (15). a Press fit the bearing until the end face of the outer lace comes in contact with the stepped part of the cover. a After press fitting the bearing, drop transmission oil (T030 or T010) about 6 cc to the sliding portion and rotate the bearing ten turns to run in the bearing.

2) Install the O-ring to the cover side of case (6), install case (6) to shaft (31), and secure it with two bolts. 2 O-ring: Grease (G2-LI) a Using a press, push the inner race of ball bearing (7) to press fit the bearing until the end face of inner race comes in contact with the stepped part of the shaft. 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 bushing 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). a Using a press, press fit the bearing until the end face of outer race comes in contact with the stepped part of the case. a After press fitting the bearing, drop transmission oil (T030 or T010) about 6 cc to the sliding portion and rotate the bearing ten turns to run in the bearing.

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50-145

Power train Disassembly and assembly of PTO and transfer

Disassembly and assembly of PTO and transfer

50-146

50-146

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Power train Disassembly and assembly of PTO and transfer

WA1200-6

50-147

Power train Disassembly and assembly of PTO and transfer

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-148

Part No.

Part name

a If no stamping mark of "UP" is found in the cage, stamp mark "UP" on the side of the gauge cast hole to prevent wrong installation.

SMT-890-1200 1 SMT-890-1210 SMT-890-1220 SMT-890-1240 3 SMT-890-1250 C SMT-890-5600 SMT-890-5610 5 SMT-890-5620 SMT-890-5630 SMT-890-5640 6 SMT-890-5710

Assembly Drawing q Socket q Guide Test/J Test/J Assembly Drawing q Gear q Shaft q Carburetor q Plate Test Jig

t 1 t t t t 1 1 1 1

Q Q Q Q Q

t 1 N Q t t t t t 1 1 1 1 1 N N N N N Q Q Q Q Q

Disassembly 50-148 1. Speed sensor Loosen the locknut and remove speed sensor (1). 2. Cover Remove 12 mounting bolts to remove cover (2). 3. PTO gear 1 (gear D) 1) Remove six mounting bolts to remove cage (3) and shim (4). a Note the number and thickness of the shims for installation purpose. 2) Remove the outer race of taper roller bearing (5) from cage (3). a Use a bearing puller to pull out. 3) Remove coupling (6). 4) Remove snap ring (7) from coupling (6). 5) Remove gear (8). 6) Remove snap ring (9) from gear (8). 7) Remove the inner races of taper roller bearings (5) and (10) from gear (8). a Use a bearing puller to pull out. 4. PTO gear 2 (gear C) 1) Remove eight mounting bolts to remove cage (11) and shim (12). a Note the number and thickness of the shims for installation purpose.

2) Remove the outer race of taper roller bearing (13) from cage (11). a Use a press to pull out. 3) Remove gear (14). 4) Remove the inner races of taper roller bearings (13) and (15) from gear (14). a Use a bearing puller to pull out. 5. PTO gear 3 (gear B) 1) Remove eight mounting bolts to remove cage (16) and shim (17). a Note the number and thickness of the shims for installation purpose. 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 installation.

50-148

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Power train Disassembly and assembly of PTO and transfer

2) Remove the outer race of taper roller bearing (18) from cage (16). a Use a press to pull out. 3) Remove gear (19). 4) Remove the inner races of taper roller bearings (18) and (20) from gear (19). a Use a bearing puller to pull out. 6. Modulating clutch gear (gear E) 1) Remove eight mounting bolts to remove cage (21) and shim (22). a Note the number and thickness of the shims for installation purpose. 2) Remove the outer races of taper roller bearings (23) and (24) from cage (21). a Use a bearing puller and a press to pull out. 3) Remove gear (25). 4) Remove the snap ring (26), and remove the outer race of roller bearing (27) from gear (25). a Use a bearing puller to pull out. 5) Remove the inner races of taper roller bearings (23) and (28) from gear (25). a Use a bearing puller to pull out. 7. Input gear (gear A) 1) Remove the mounting bolts to remove holder (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). a Use a bearing puller to pull out. 6) Remove spacer (34). 7) Sling and remove gear (35). 8) Remove the inner races of taper roller bearings (33) and (36) from gear (35). a Use a bearing puller to pull out.

9) Remove eight mounting bolts to remove cage (37) and shim (38). a Note the number and thickness of the shims for installation purpose. 10)Remove the outer race of taper roller bearing (36) from cage (37). a Use a bearing puller to pull out. 8. Case Remove the outer races of taper roller bearings (10), (15) and (20) from case (39). a Use a bearing puller to pull out. 50-149 Assembly a Adjust the preload of the taper roller bearing for the input transfer according to the following procedure. 1) Adjust preload of bearings of A, B, C, D and E shafts independently. Adjust the preload along each axis according to Steps 1 to 6 below. a First adjust the preload of bearings of shafts A and E, then remove the gears of shafts A and E to adjust the preload of bearings of shafts B, C and D. Then, install the gears of shafts A and E with the shim thickness as adjusted previously.

2) After the preload adjustment, check that the gears are free from play.
Gear A to B A to C A to D A to E Reduction ratio 68/74 = 0.919 68/74 = 0.919 68/74 = 0.919 58/74 = 0.784

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Power train Disassembly and assembly of PTO and transfer

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.

2. Input gear (gear A) 1) Install the outer race of taper roller bearing (36) to cage (37). a Using a press, press fit the outer race until 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 its end face comes in contact with the stepped part of the gear. 4) Install gear (35). 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. 5) Install spacer (34). 6) Install the outer race of taper roller bearing (33) to cage (31). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage.

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 extra liquid gasket. a Press fit the oil seal until the flange of the tool C1 comes in contact with the cage. 2 Oil seal lip: Grease (G2-LI)

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: Adhesive (LT-2) 3 Mounting bolt: 245 to 309 Nm {25.0 to 31.5 kgm} 9) Loosen the mounting bolts of cage (37) to remove temporarily-assembled shims (38). Tighten eight mounting bolts and retighten to 4.9 Nm {0.5 kgm}.

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Power train Disassembly and assembly of PTO and transfer

10)Rotate the gear (35) 20 turns by hand, and then check the tightening torque of the mounting bolts of cage (37).

14)Using a push-pull scale, measure the turning force at the tip of the gear teeth, and check 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. 16)Install holder (29) with the bolts. 2 Mounting bolt threaded portion: Adhesive (LT-2) 3 Mounting bolt: 824 to 1,030 Nm {84 to 105 kgm}

11)If the tightening torque has changed, repeat Steps 9) and 10). 12)If the tightening torque has not changed, loosen the mounting bolts of cage (37) and measure clearance A at three places and 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) 1) Install the inner races of taper roller bearings (28) and (23) to gear (25). a Using a press, press fit the inner race until its end face comes in contact with the stepped part of the gear.

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}

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2) Install the outer race of roller bearing (27) to gear (25), and secure it by using snap ring (26). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the gear.

6) Using tool C5, rotate gear (25) 20 turns, and then check the tightening torque of the mounting bolts of cage (21).

7) If the tightening torque has changed, repeat Steps 5) and 6). 3) Install gear (25). 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. 4) Install the outer races of taper roller bearings (23) and (24) to cage (21). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 5) Install cage (21) and tighten eight mounting bolts to 4.9 Nm {0.5 kgm} without fitting shim (22). 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. 8) If the tightening torque has not changed, loosen the mounting bolts of cage (21), insert shim (22) and tighten cage (21) 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 9) Using tool C5, measure the turning torque at the center of the gear, and check that it is within the standard value. a Gear turning torque: 1.76 to 2.94 Nm {0.18 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 5) to 9), do not move case (39) such as by turning upside down.

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4. PTO gear 3 (gear B) 1) Install the inner races of taper roller bearings (20) and (18) to gear (19). a Using a press, press fit the inner race until its end face comes in contact with the stepped part of the gear. 2) Install 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.) 3) Install the outer race of taper roller bearing (18) to cage (16). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 4) Install cage (16) with the O-ring and tighten eight mounting bolts to 4.9 Nm {0.5 kgm} without fitting shim (17). 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. a Install the cage with the stamp "UP" up, and check that the lubrication cast hole "A" is at the top.

5) Using tool C3 (2/2), rotate gear (19) 20 turns, and then check the tightening torque of the mounting bolts of cage (16).

6) If the tightening torque has changed, repeat Steps 4) and 5).

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7) If the tightening torque has not changed, loosen the mounting bolts of cage (16) 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 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.

9) Using tool C3 (2/2), 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 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 4) to 9), do not move case (39) such as by turning upside down.

8) Insert shim (17) of the thickness which is reduced by 0.10 to 0.20 mm from the average value of clearance A measured in Step 8), and tighten cage (16) with eight bolts. 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

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5. PTO gear 2 (gear C) 1) Install the inner races of taper roller bearings (15) and (13) to gear (14). a Using a press, press fit the inner race until its end face comes in contact with the stepped part of the gear. 2) Install 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 identification 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.) 3) Install the outer race of taper roller bearing (13) to cage (11). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 4) Install cage (11) with the O-ring and tighten eight mounting bolts to 4.9 Nm {0.5 kgm} without fitting shim (12). 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. a Install the cage with the stamp "UP" up, and check that the lubrication cast hole "A" is at the top.

5) Using tool C6, rotate gear (14) 20 turns, and then check the tightening torque of the mounting bolts of cage (11).

6) If the tightening torque has changed, repeat Steps 4) and 5).

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7) If the tightening torque has not changed, loosen the mounting bolts of cage (11) 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 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.

9) Using tool C6, 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 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 4) to 9), do not move case (39) such as by turning upside down.

8) Insert shim (12) of the thickness which is reduced by 0.10 to 0.20 mm from the average value of clearance A measured in Step 7), and tighten cage (16) with eight bolts. 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

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6. PTO gear 1 (gear D) 1) Install the inner races of taper roller bearings (10) and (5) to gear (8). a Using a press, press fit the inner race until its end face comes in contact with the stepped part of the gear. 2) Install snap ring (9) to gear (8). 3) Install gear (8). 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. 4) Install snap ring (7) to coupling (6). 5) Install coupling (6). 6) Install the outer race of taper roller bearing (5) to cage (3). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 7) Install cage (3) with the O-ring and tighten eight mounting bolts to 4.9 Nm {0.5 kgm} without fitting shim (4). 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.

8) Using tool C3 (1/2), rotate gear (8) 20 turns, and then check the tightening torque of the mounting bolts of cage (3).

9) If the tightening torque has changed, repeat Steps 7) and 8). 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 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.

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11)Insert shim (4) of the thickness which is reduced by 0.10 to 0.20 mm from the average value of clearance A measured in Step 10), and tighten cage (3) with eight bolts.

8. Speed sensor Install speed sensor (1) and secure it with the lock nut. 2 Threaded portion of sensor: 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 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 7) to 12), do not move case (39) such as by turning upside down.

7. Cover Fit the gasket and install cover (2) with 12 bolts.

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Disconnection and connection of transmission assembly, transfer, and parking brake assembly 50-159

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Power train Disconnection and connection of transmission assembly, transfer, and parking brake assembly

a When re-assembling the transmission assembly, or the transfer and parking brake assemblies, O-rings, seals, and other consumable parts must be replaced with new ones. Prepare the following kit components. KIT No.: 42C-15-05280 a For details of KIT No., see the end of this section. 50-160 Disconnection 1. Preparation work Set Raise the assembly with the transfer vertical and support the transmission with blocks, etc. so that the transmission is kept level. 2. Lubrication tube 1) Remove the two joints from each lubrication tube, and remove lubrication tubes (1), (2), (3), (4), and (5). a Remove the tube clamp. 2) Remove two mounting bolts to remove block (6). 3) Remove two mounting bolts to remove block (7). 3. Oil filter assembly 1) Remove one mounting bolt and three sets of nuts and stud bolts, then remove cover (8) and four spacers (9). 2) Remove three mounting bolts, then remove oil filter assembly (10) and cover (11). 4. FR clutch valve assembly 1) Remove four mounting bolts, then remove reverse clutch ECMV assembly (12), and bypass fill and drain valve assembly (13). a Two kinds of mounting bolts different in length are used. Put matchmarks to indicate their installed positions. 2) Remove four mounting bolts, then remove forward clutch ECMV assembly (14) and bypass fill valve assembly (15). a Two kinds of mounting bolts different in length are used. Put matchmarks to indicate their installed positions.

5. Speed clutch valve assembly 1) Remove four mounting bolts, then remove 1st clutch ECMV assembly (16) and bypass fill valve assembly (17). a Two kinds of mounting bolts different in length are used. Put matchmarks to indicate their installed positions. 2) Remove four mounting bolts, then remove two assemblies, 2nd clutch ECMV assembly and 3rd clutch ECMV assembly (18). a Two kinds of mounting bolts different in length are used. Put matchmarks to indicate their installed positions. 6. Lubrication relief valve assembly Remove three mounting bolts, then remove lubrication relief valve assembly (19). a Two kinds of mounting bolts different in length are used. Put matchmarks to indicate their installed positions. 7. Valve seat 1) Remove four mounting bolts and remove valve seat (20). a Two kinds of mounting bolts different in length are used. Put matchmarks to indicate their installed positions. 2) Remove valve seat (21). 3) Remove 14 mounting bolts and remove valve seat (22). 8. Breather 1) Remove two breathers (23) and remove two elbows (24). 2) Remove four mounting bolts and flange (25).

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Power train Disconnection and connection of transmission assembly, transfer, and parking brake assembly

9. Transmission assembly, and transfer and parking brake assembly 1) Sling transmission assembly (26). 2) Remove 23 mounting bolts, and disconnect transmission assembly (26) from transfer and parking brake assembly (27). k When removing the transmission, pay careful attention so that the transfer and parking brake assembly does not fall over. a Move the transmission to the input shaft side until the output shaft of transmission comes off the transfer. a Place the removed transmission assembly on the block with the input shaft side up. a For procedures for disassembling the transmission, see "Assembly and disassembly of transmission". a For procedures for disassembling the transfer and parking brake, see "Assembly and disassembly of transfer", and "Assembly and disassembly of parking brake". 10. Strainer 1) Remove two mounting bolts to remove drain plug (28). 2) Remove four mounting bolts from each cover and remove four covers (29). 3) Remove four springs (30) and four magnets (31). 4) Remove four cases (32).

50-161 Connection 1. Preparation work Place the transfer vertical and support it with blocks. 2. Strainer 1) Install four cases (32) with the O-ring. 2 O-ring on periphery: Grease (G2-LI) 2) Install four magnets (31) and four springs (30). 3) Install four covers (29) with the O-ring by using four bolts each. 4) Install valve seat (28) with the O-ring by using two bolts. 2 O-ring: Grease (G2-LI) 3. Transmission assembly, and transfer and parking brake assembly 1) Fit the O-ring to the joint portion (26) of transfer and parking brake assembly (27) connecting with transmission assembly (26). 2 O-ring: Grease (G2-LI) 2) Sling transmission assembly (26) and install it to transfer assembly (27) with 23 bolts. k When installing the transmission, pay careful attention so that the transfer and parking brake assembly does not fall over. a After installing the transmission, support the bottom of the transmission with blocks. 4. Breather 1) Install flange (25) with four bolts. 2 Mating face on flange with case: Liquid gasket (LG-5) 2) Install two elbows (24) and install two breathers (23). 2 Elbow and breather: Liquid gasket (LG-5)

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Power train Disconnection and connection of transmission assembly, transfer, and parking brake assembly

5. Valve seat 1) Install valve seat (22) with O-rings by using 14 bolts. 3 Hexagon socket head bolt (six bolts): 58.8 to 73.5 Nm {6.0 to 7.5 kgm} 2) Install valve seat (21) with O-rings. 3) Install valve seat (20) with O-rings by using four bolts. a Two kinds of mounting bolts different in length are used. Check their installed positions with matchmarks that were put at the time of disassembly. 3 Mounting bolt: 58.8 to 73.5 Nm {6.0 to 7.5 kgm} 6. Lubrication relief valve assembly Install lubrication relief assembly (19) with O-rings by using three bolts. a Two kinds of mounting bolts different in length are used. Check their installed positions with matchmarks that were put at the time of disassembly. 3 Mounting bolt: 58.8 to 73.5 Nm {6.0 to 7.5 kgm} 7. Speed clutch valve assembly a Before installation, make sure that you have picked up the speed clutch ECMV assembly and it is not the FR clutch ECMV assembly. The speed clutch ECMV assembly uses hexagonal head bolts as cover mounting bolts. 1) Install two assemblies with O-rings, 3rd clutch ECMV assembly and 2nd clutch ECMV assembly (18) by using four bolts each. a Two kinds of mounting bolts different in length are used. Check their installed positions with matchmarks that were put at the time of disassembly. 3 Mounting bolt: 27.4 to 34.3 Nm {2.8 to 3.5 kgm}

2) Install bypass fill valve assembly (17) with O-rings and 1st clutch ECMV assembly (16) with the O-rings by using four bolts. a Two kinds of mounting bolts different in length are used. Check their installed positions with matchmarks that were put at the time of disassembly. 3 Mounting bolt: 27.4 to 34.3 Nm {2.8 to 3.5 kgm} 8. FR clutch valve assembly a Before installation, make sure that you have picked up the FR clutch ECMV assembly and it is not the speed clutch ECMV assembly. The FR clutch ECMV assembly uses hexagonal socket head bolts as cover mounting bolts. 1) Install bypass fill valve assembly (15) with O-rings and forward clutch ECMV assembly (14) with the O-rings by using four bolts. a Two kinds of mounting bolts different in length are used. Check their installed positions with matchmarks that were put at the time of disassembly. 3 Mounting bolt: 27.4 to 34.3 Nm {2.8 to 3.5 kgm} 2) Install bypass fill valve assembly (13) with O-rings and reverse clutch ECMV assembly (12) with the O-rings by using four bolts. a Two kinds of mounting bolts different in length are used. Check their installed positions with matchmarks that were put at the time of disassembly. 3 Mounting bolt: 27.4 to 34.3 Nm {2.8 to 3.5 kgm} 9. Oil filter 1) Install cover (11) with O-rings and oil filter assembly (10) by using three bolts. 3 Mounting bolt: 58.8 to 73.5 Nm {6.0 to 7.5 kgm} 2) Install three studs, then install four spacers (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}

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Service kit parts list 50-163 KIT No.: 42C-15-05280 (Connection service kit for transmission and transfer assemblies) Fig. No.: Y0 Y99-0000002 (K06) (Transfer case)
Index 5 7 13 21 22 23 Part No. 42C-15-18240 07000-72130 07000-72115 07000-72125 07000-73045 07000-72070 Part name O-RING O-RING O-RING O-RING O-RING O-RING Q'ty 1 8 4 2 1 1

Service kit parts list 50-163 KIT No.: 42C-15-05280 (Connection service kit for transmission and transfer assemblies) Fig. No.: Y0 Y99-0000002 (K06) (Transfer case)
Index 8 10 23 26 Part No. 07000-72135 07000-75185 569-15-59110 07000-72135 Part name O-RING O-RING O-RING O-RING Q'ty 1 1 1 1

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50-164 Service kit parts list KIT No.: 42C-15-05280 (Connection service kit for transmission and transfer assemblies) Fig. No.: Y0 Y99-0000006 (K06) (Transfer output shaft)
Index 4 8 9 14 20 Part No. 07000-75210 07012-50140 562-15-39970 42C-15-05010 42C-15-13332 Part name O-RING SEAL O-RING SHIM KIT SEAL Q'ty 1 1 2 1 1

50-164 Service kit parts list KIT No.: 42C-15-05280 (Connection service kit for transmission and transfer assemblies) Fig. No.: Y0 Y99-0000006 (K06) (Transmission piping)
Index 34 Part No. 07000-73028 Part name O-RING Q'ty 1

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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 9 12 13 22 24 25 32 33 34 36 Part No. 07000-75495 175-15-59240 562-15-19550 07000-75495 42C-15-13332 07012-50140 07000-72018 07000-72016 07000-73028 07002-61023 Part name O-RING RING RING O-RING SEAL SEAL O-RING O-RING O-RING O-RING Q'ty 1 1 1 1 1 1 1 1 1 1

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Disassembly and assembly of transmission assembly

50-16

50-166

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50-167

Power train Disassembly and assembly of transmission assembly

50-168

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Power train Disassembly and assembly of transmission assembly

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Power train Disassembly and assembly of transmission assembly

Special tools
Symbol

50-170
Necessity Q'ty New/redesign Sketch

Part No.

Part name

1 SMT-890-1410 Socket 8 SMT-890-4100 Guide

t 1 t 1

Q Q

Disassembly 50-170 1. Preparation work Set the transmission assembly with the input shaft up on the block. 2. Case 1) Remove seven sleeves (1). a To remove the sleeve, apply a bearing puller to the groove in the inner periphery of each sleeve. 2) Remove 23 mounting bolts to remove case (2). 3. Housing Remove 24 long bolts and 6 short bolts to remove housing (3). 4. Input shaft, reverse clutch carrier, reverse sun
gear assembly

5) Remove eight mounting bolts to remove cage (10). a Use forcing screws to pull out. 6) Remove two seal rings (11) from cage (10). 7) Remove snap ring (12) and then remove gear (13). 8) Remove snap ring (14). 9) Remove shaft (15). a Use a press to pull out. 10)Remove seal ring (16) from shaft (15). 11)Remove snap ring (17) and then remove gear (18). 12)Remove ball bearing (19) from shaft (15). a Use a press to pull out. 13)Remove shaft (20) and ball (21) from carrier (22). a Remove four sets. 14)Remove gear (23), and then remove two needle bearings (24) and two thrust washers (25). a Remove four sets. 15)Remove the inner race of roller bearing (26). a Use a bearing puller to pull out. 5. Reverse clutch plate and disc 1) Remove six springs (27). a The length of spring differs depending on clutch types. Attach a tag to each spring to identify its mounting position. 2) Remove eight plates (28) and seven discs (29) alternately while removing 48 springs (30). 6. Reverse clutch ring gear Remove ring gear (31).

1) Sling the end of the input shaft to remove input shaft, reverse clutch carrier, and reverse sun gear assembly (4). a Since the inner and outer races of the taper roller bearing at the bottom of the carrier are separated, lift the assembly straight up, taking care not to pry the races. 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). a Use a bearing puller to pull out.

50-170

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Power train Disassembly and assembly of transmission assembly

7. Reverse clutch housing and piston 1) Remove housing (32). a Remove it and the piston as a unit. 2) Remove piston (33) from housing (32). 3) Remove seal ring (34) from housing (32). 4) Remove seal ring (35) from piston (33). 8. Coupler ring gear 1) Remove eight mounting bolts to remove plate (36). 2) Remove ring gear (37). 3) Remove snap ring (38) from ring gear (37). 9. Forward clutch plate and disc 1) Remove six pins (39) and 12 pins (40). a The length of pin differs depending on clutch types. Attach a tag to each pin to identify its mounting position. 2) Remove six springs (41). a The length of spring differs depending on clutch types. Attach a tag to each spring to identify its mounting position. 3) Remove nine plates (42) and eight discs (43) alternately while removing 72 springs (44). 10. Forward clutch ring gear Remove ring gear (45). 11. Forward clutch housing and piston 1) Remove housing (46). a Remove it and the piston as a unit. 2) Remove piston (47) from housing (46). 3) Remove seal ring (48) from housing (46). 4) Remove seal ring (49) from piston (47).

12. 3rd clutch plate and disc 1) Remove six springs (50). a The length of spring differs depending on clutch types. Attach a tag to each spring to identify its mounting position. 2) Remove five plates (51) and four discs (52) while removing 30 springs (53). 13. Forward clutch and 3rd clutch carrier assembly 1) Remove four mounting bolts to remove collar (54). 2) Remove two seal rings (55) from collar (54). 3) Sling and remove forward clutch and 3rd clutch carrier assembly (56). 4) Remove snap ring (57), and then remove ball bearing (58) and gear (59). a Use a press to pull out. 5) Remove collar (60) from ball bearing (58). a Use a press to pull out. 6) Remove shaft (62) and ball (63) from carrier (64). a Remove four sets. 7) Remove gear (65), and then remove two needle bearings (66) and two thrust washers (67). a Remove four sets. 8) Remove the outer race of roller bearing (26) from carrier (64). a Use a bearing puller to pull out. 14. 3rd clutch ring gear 1) Remove eight mounting bolts to remove plate (68). 2) Remove ring gear (69). 3) Remove snap ring (70) from ring gear (69).

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Power train Disassembly and assembly of transmission assembly

15. 3rd clutch housing and piston 1) Remove housing (71). a Remove it and the piston as a unit. 2) Remove piston (72) from housing (71). 3) Remove seal ring (73) from housing (71). 4) Remove seal ring (74) from piston (72). 16. 2nd clutch plate and disc 1) Remove six springs (75). a The length of spring differs depending on clutch types. Attach a tag to each spring to identify its mounting position. 2) Remove six pins (76) and 12 pins (77). a The length of pin differs depending on clutch types. Attach a tag to each pin to identify its mounting position. 3) Remove four plates (78) and three discs (79) alternately while removing 24 springs (80). 17. 2nd clutch ring gear Remove ring gear (81). 18. 2nd clutch housing 1) Remove housing (82). a Remove it and the piston as a unit. 2) Remove piston (83) from housing (82). 3) Remove seal ring (84) from housing (82). 4) Remove seal ring (85) from piston (83). 19. 2nd clutch sun gear Remove gear (86).

20. 2nd clutch carrier and 1st clutch assembly 1) Remove 2nd clutch carrier and 1st clutch assembly (87). a Apply a puller to the bolt hole in the carrier to pull out the assembly. 2) Remove 30 mounting bolts to remove cage (88). 3) Remove snap ring (89), and then remove spacer (90) from cage (88). a Remove the snap ring while pressing the springs with a press. 4) Remove three springs (91) from cage (88). 5) Remove piston (92) from cage (88). 6) Remove seal ring (93) from piston (92). 7) Remove snap ring (94), and then remove ball bearing (95) from cage (88). a Use a bearing puller to pull out. 8) Remove snap ring (96), and then remove collar (97) from cage (88). 9) Remove ball bearing (98) from cage (88). a Use a bearing puller to pull out. 10)Remove seal rings (99) and (100) from cage (88). 11)Remove hub (101). 12)Remove two seal rings (102) from hub (101). 13)Remove nine discs (103), eight plates (104), and nine springs (105) alternately. 14)Remove snap ring (106) from carrier (107). 15)Remove shaft (108) and ball (109) from carrier (107). 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). a Use a press to pull out. 3) Remove seal ring (118) from cage (116). 4) Remove snap ring (119), and then remove ball bearing (120) from shaft (117). a Use a press to pull out. 5) Remove seal ring (121) from shaft (117).

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Assembly Precautions for assembly

50-173 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 clearance "A" between collar (54) and 3rd gear (59) all around, and check that the measurements 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.

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.

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2) Repairing collar 1] Grind the end face of collar (54) (19M-15-12850) so that clearance "A" is 0.1 mm. 2] After re-assembling, insert a gauge into the clearance between 3rd gear (59) and 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 procedure. D: Grinding surface E: Surface roughness of the grinding surface shall be RR (25S or less).

2) Fix insertion tool D8 to pinion shaft (20) with bolts. a Insertion tool D8 prevents the rollers of bearings (24) from falling down inside, allowing smooth insertion of the pinion shaft.

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 bearings (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 carrier hole so that pinion shaft (20) (19M-15-12531) is inserted smoothly.

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4) Loosen bolts of tool D8, and remove tool D8 from pinion shaft (20).

2) Fix insertion tool D8 to pinion shaft (62) with bolts. a Insertion tool D8 prevents the rollers of bearings (66) from falling down inside, allowing 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 bearings (66) to planetary gear (65) for the 3rd clutch. Set the planetary gear with thrust washer (67) on both sides to 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 carrier hole so that pinion shaft (62) (19M-15-00092) is inserted smoothly.

3) Cool down pinion shaft (62) with dry ice, and insert the shaft with ball (63) into carrier (64).

4) Loosen bolts of tool D8, and remove tool D8 from pinion shaft (62).

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5) Install plate (36) to carrier (64), temporarily fix it with bolts, and reverse the carrier assembly so that pinion shaft (62) and ball (63) are not removed.

6) Reverse the forward and 3rd clutch carrier assembly, and remove the temporarily fixed plate (36). 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). 2) Using the push tool, press fit bearing (58) to collar (60). 3) Press fit the assembly of bearing (58) and collar (60) to forward and 3rd carrier (64). 4) Install snap ring (57). 5) Install plate (122) to forward and 3rd carrier (64) with bolts (123) and washers. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98 to 123 Nm {10 to 12.5 kgm}

5. Assembling 2nd clutch carrier 1) Place 2nd clutch carrier (107) (19M-15-12312) with the output side (with a ball groove) up. Install bearings (111) to planetary gear (110) for the 2nd clutch. Set the planetary gear with thrust washer (112) on both sides to carrier (107). a Align the holes in the planetary gear, bearings, and thrust washers with the carrier hole so that pinion shaft (108) is inserted smoothly. 2) Cool down pinion shaft (108) with dry ice, and insert the shaft with ball (109) into carrier (107). 3) Install snap ring (124).

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Assembly

50-17

1. Output shaft assembly and housing 1) Install seal ring (121) to shaft (117). a Use new seal rings. 2 Seal ring: Grease (G2-LI) 2) Install ball bearing (120) to shaft (117), and secure it by using snap ring (119). a Using a press, press fit the bearing until the end face of inner race comes in contact with the stepped part of the shaft. 3) Install seal ring (118) to cage (116). 2 Seal ring: 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. 2 Mounting bolt threaded portion: 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". 1) Set two thrust washers (112) and two needle bearings (111) to gear (110), and install the gear to carrier (107). a Take care not to dent the thrust washers. a Install four sets. 2) Install shaft (108) with ball (109) to carrier (107). a Aligning the ball with the carrier groove, press fit the shaft by using a press until the shaft is flush with the carrier. a Install four sets.

3) Install snap ring (106) in carrier (107). 4) Install nine discs (103), eight plates (104), and nine springs (105) in carrier (107) alternately. 5) Install two seal rings (102) to hub (101). 2 Seal ring: Grease (G2-LI) 6) Install hub (101) in carrier (107). 7) Install seal rings (100) and (99) to cage (88). 2 Seal ring: Grease (G2-LI) a Seal ring (100) has its installed direction. Install the seal ring as shown in the drawing below.

8) Install ball bearing (98) to cage (88). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 9) Install collar (97) to cage (88), and secure it by using snap ring (96). 10)Install ball bearing (95) to cage (88), and secure it by using snap ring (94). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage.

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11)Install seal ring (93) to piston (92). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Install the seal ring as shown in the drawing below.

4. 2nd clutch housing 1) Install seal ring (85) to piston (83). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Install the seal ring as shown in the drawing below.

12)Install piston (92) to cage (88). 13)Install three springs (91) to cage (88). 14)Install spacer (90) and secure it by using snap ring (89). a Using a press, compress the spring, and install the spacer and snap ring. a Load at installed length of spring: 1,697 N {173 kg} 15)Install cage (88) to carrier (107) with 30 bolts. 2 Mounting bolt threaded section: 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).

2) Install seal ring (84) to housing (82). 2 Seal rings Grease (G2-LI) a The seal ring has its installed direction. Install the seal ring as shown in the drawing below.

3) Install piston (83) to housing (82). 4) Install housing (82). 5. 2nd clutch ring gear Install ring gear (81).

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6. 2nd clutch plate and disc 1) Install four plates (78) and three discs (79) alternately while installing 24 springs (80). 2) Install 12 pins (77) and six pins (76). a The length of pin differs depending on clutch types. Check the length of pin before installation. a Pin length (77): 208 mm, (76): 223 mm 3) Install six springs (75). a The length of spring differs depending on clutch types. Check the length of spring before installation. a Free length of spring: 56.9 mm 7. 3rd clutch housing and piston 1) Install seal ring (74) to piston (72). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Check the installed direction before installation (similarly to that for 2nd clutch). 2) Install seal ring (73) to housing (71). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Check the installed direction before installation (similarly to that for 2nd clutch). 3) Install piston (72) to housing (71). 4) Install housing (71). 8. 3rd clutch ring gear 1) Install snap ring (70) to ring gear (69). 2) Install ring gear (69). 3) Install plates (68) with eight bolts. 2 Mounting bolt threaded portion: Adhesive (LT-2) 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

9. Forward and 3rd clutch carrier assembly 1) Install the outer race of roller bearing (26) to carrier (64). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the carrier. 2) Set two thrust washers (67) and two needle bearings (66) to gear (65), and install the gear to carrier (64). a Take care not to dent thrust washers. a Install four sets. 3) Install shaft (62) with ball (63) to carrier (64). a Aligning the ball with the carrier groove, press fit the shaft by using a press until the shaft is flush with the carrier. a Install four sets. 4) Install plate (59) to carrier (64). 5) Press fit collar (60) into ball bearing (58) with a press. a Using a press, press fit the collar until the stepped part of the collar comes in contact with the end face of the inner race. 6) Install ball bearing (58) to carrier (64), and secure it by using snap ring (57). a Using a press, press fit the bearing until the end face of the outer race comes in contact with the stepped part of the carrier. 7) Install forward clutch and 3rd clutch carrier assembly (56). 8) Install two seal rings (55) to collar (54). a Use new seal rings. 2 Seal ring: Grease (G2-LI) 9) Install collar (54) by using four bolts. 2 Mounting bolt threaded section: Adhesive (LT-2) 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

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10. 3rd clutch plate and disc 1) Install five plates (51) and four discs (52) alternately while installing 30 springs (53). 2) Install six springs (50). a The length of spring differs depending on clutch types. Check the length of the springs before installation. a Free length of spring: 68.8 mm 11. Forward clutch housing and piston 1) Install seal ring (49) to piston (47). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Check the installed direction before installation (similarly to that for 2nd clutch). 2) Install seal ring (48) to housing (46). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Check the installed direction before installation (similarly to that for 2nd clutch). 3) Install piston (47) to housing (46). 4) Install housing (46). 12. Forward clutch ring gear Install ring gear (45). 13. Forward clutch plate and disc 1) Install nine plates (42) and eight discs (43) alternately while installing 72 springs (44). 2) Install six springs (41). a The length of spring differs depending on clutch types. Check the length of the springs before installation. a Free length of spring: 168 mm 3) Install 12 pins (40) and six pins (39). a The length of pin differs depending on clutch types. Check the length of pins before installation. a Pin length (40): 315 mm, (39): 315 mm

14. Coupler ring gear 1) Install snap ring (38) to ring gear (37). 2) Install ring gear (37). 3) Install plates (36) with eight bolts. 2 Mounting bolt threaded section: Adhesive (LT-2) 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm} 15. Reverse clutch housing and piston 1) Install seal ring (35) to piston (33). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Check the installed direction before installation (similarly to that for 2nd clutch). 2) Install seal ring (34) to housing (32). 2 Seal rings: Grease (G2-LI) a The seal ring has its installed direction. Check the installed direction before installation (similarly to that for 2nd clutch). 3) Install piston (33) to housing (32). 4) Install housing (32). 16. Reverse clutch ring gear Install ring gear (31). 17. Reverse clutch plate and disc 1) Install eight plates (28) and seven discs (29) alternately while installing 48 springs (30). 2) Install six springs (27). a The length of spring differs depending on clutch types. Check the length of the springs before installation. a Free length of spring: 133 mm

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18. Input shaft, reverse clutch carrier, reverse clutch sun gear assembly a See item 2 in "Precautions for assembly". 1) Install the inner race of roller bearing (26) to carrier (22). a Using a press, press fit the inner race until its end face comes in contact with the stepped part of the carrier. 2) Set two thrust washers (25) and two needle bearings (24) to gear (23), and install the gear to carrier (22). a Take care not to dent thrust washers. a Install four sets. 3) Install shaft (20) with ball (21) to carrier (22). a Aligning the ball with the carrier groove, press fit the shaft by using a press until the shaft is flush with the carrier. a Install four sets. 4) Install ball bearing (19) to shaft (15). a Using a press, press fit the bearing until the end face of the inner race comes in contact with the stepped part of the shaft. 5) Install gear (18) and secure it with snap ring (17). 6) Install shaft (15) to carrier (22). a Using a press, press fit the outer race of the ball bearing until its end face comes in contact with the stepped part of the carrier. 7) Install snap ring (14). 8) Install gear (13) and secure it with snap ring (12). 9) Install two seal rings (11) to cage (10). 2 Seal ring: Grease (G2-LI)

10)Install cage (10) to gear (22) by using eight bolts. 2 Mounting bolt threaded section: Adhesive (LT-2) 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm} 11)Install ball bearing (9) to cage (7). a Using a press, press fit the inner race until its end face come in contact with the stepped part of the cage. 12)Install cage (7) to cage (10). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 13)Using tool D1, install ball bearing (8) to cage (7). a For tool D1, see the "Sketches of special tools". a Using a press, press fit the inner and outer races of the ball bearing at the same time until the end face of the outer race comes in contact with the stepped part of the cage. 14)Install spacer (6) and secure it with snap ring (5). 15)Install seal ring (16) to shaft (15). a Use a new seal ring. 2 Seal ring: Grease (G2-LI) 16)Sling the end of the input shaft to install input shaft, reverse clutch carrier, and reverse clutch sun gear assembly (4). a Since the inner and outer races of the roller bearing at the bottom of the carrier are 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.

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Service kit parts list KIT No.: 42C-15-05051 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K03) (1st clutch and 2nd housing)
Index 3 4 7 17 26 28 Part No. 562-15-19320 198-15-29280 426-15-19220 19M-15-19280 19M-15-19220 19M-15-19250 Part name RING RING RING RING RING RING Q'ty 1 1 1 2 1 1

Service kit parts list KIT No.: 42C-15-05051 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K03) (Housing)
Index 3 6 11 13 20 22 Part No. 19M-15-19220 19M-15-19250 19M-15-19230 19M-15-19240 19M-15-19220 19M-15-19250 Part name RING RING RING RING RING RING Q'ty 1 1 1 1 1 1

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Service kit parts list KIT No.: 42C-15-05051 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K03) (Carrier)
Index Part No. 50 19M-15-19280 Part name RING Q'ty 2

Service kit parts list KIT No.: 42C-15-05051 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K03) (Input and output shafts)
Index Part No. 15 195-15-39260 Part name RING Q'ty 2

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Service kit parts list KIT No.: 42C-15-05290 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K07) (Control valve)
Index 3 4 5 6 7 8 9 13 14 20 21 Part No. 07002-61623 07002-61623 07002-62034 07002-62034 07000-73032 07000-73048 07000-72018 07000-72018 07000-72021 07000-72018 07000-72021 Part name O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING O-RING Q'ty 3 7 7 1 2 1 1 7 8 6 5

Service kit parts list KIT No.: 42C-15-05290 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K07) (Control valve)
Index 9 11 12 13 14 15 Part No. 07000-72020 07000-02012 42C-15-15980 07000-12016 07000-02018 203-60-62190 Part name O-RING O-RING O-RING O-RING O-RING O-RING Q'ty 2 2 2 2 2 2

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Service kit parts list KIT No.: 42C-15-05290 (Service kit for assembling transmission)) Fig.No.: Y0 Y99-0000002 (K07) (Control valve) (Drain)
Index 10 12 13 14 15 16 20 Part No. 07000-72020 07000-02012 42C-15-15980 07000-12016 07000-02018 203-60-62190 07002-61823 Part name O-RING O-RING O-RING O-RING O-RING O-RING O-RING Q'ty 2 2 2 2 2 2 2

Service kit parts list KIT No.: 42C-15-05290 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K07) (Control valve filter)
Index 2 3 6 21 23 Part No. 170-09-17130 07000-02080 07002-61823 07002-63034 07002-62034 Part name O-RING O-RING O-RING O-RING O-RING Q'ty 1 1 1 1 1

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Service kit parts list KIT No.: 42C-15-05290 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K07) (Lubrication valve)
Index Part No. 3 07002-61023 6 07002-62434 Part name O-RING O-RING Q'ty 1 1

Service kit parts list KIT No.: 42C-15-05290 (Service kit for assembling transmission) Fig.No.: Y0 Y99-0000002 (K01) (ECMV)
Index 2* 5* 5* 5* 5* 5* Part No. 561-15-55630 07000-73025 07000-73028 07000-73035 07000-73018 07002-61023 Part name SHIM O-RING O-RING O-RING O-RING O-RING Q'ty 3 1 1 1 1 1

a One transmission unit (equipped with five ECMVs) requires five sets of components shown in the table above.

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Disassembly and assembly of transfer

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Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-189

Part No.

Part name

4) Install the two pairs of removed bolts and washers (12) 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.

SMT-890-1500 2 SMT-890-1510 SMT-890-1520 3 SMT-890-1530 D 4 SMT-890-1540 5 SMT-890-1550 6 SMT-890-1560 7 790-302-1280

Ass'y-Draw Socket q Guide Socket Socket Socket Socket Socket (Width across flats: 55 mm)
q

t t t t t t t

1 1 1 1 1 1 1

Q Q Q Q Q Q Q

t 1

Disassembly 50-189 a When removing only the parking brake assembly from the torque converter or the machine, see "Removal and installation of parking brake assembly (installed on the machine)". 1. Front coupling 1) Using tool D7, remove the mounting bolt to remove holder (1). 2) Remove coupling (2). 2. Cage 1) Remove six mounting bolts to remove cage (3) and shim (4). a Note the number and thickness of the shims for installation purpose. 2) Remove dust seal (5) from cage (3). 3) Remove oil seal (6) from cage (3). 3. Rear coupling 1) Using tool D7, remove the mounting bolt to remove holder (7). 2) Remove coupling (8). 4. Parking brake assembly 1) Remove two mounting bolts to remove flange (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 remove the four hexagonal socket head bolts.

5) Remove the remaining ten mounting bolts to remove parking brake assembly (13). a Do not remove four hexagonal socket head bolts. a Use forcing screws to pull the parking brake assembly evenly out of the shaft end, and then sling and remove the assembly. a For procedures for disassembling the parking brake, see "Disassembly and assembly of parking brake". 5. Output shaft and gear assembly 1) Remove eight mounting bolts to remove cover (14). 2) Remove output shaft and gear assembly (15). 3) Remove spacer (16) and gear (17) from shaft (18). a Using a press, pull out the spacer and gear as a unit.

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6. Intermediate gear 1) Remove two mounting bolts to remove plate (19). 2) Remove 18 mounting bolts to remove cage (20). a Use forcing screws (12 mm) to pull out the cage. a Since the inner and outer races of the roller bearing are separated, pull out the cage straight taking care not to pry the races. 3) Remove the outer race of roller bearing (21) from cage (20). a Use a bearing puller to pull out the cage. 4) Remove gear (22). a Since the inner and outer races of the roller bearing are separated, pull out the gear straight taking care not to pry the races. 5) Remove four mounting bolts to remove joint (23) from gear (22). 6) Remove the inner races of roller bearings (21) and (24) from gear (22). a Use a bearing puller to pull out the race. 7. Input gear 1) Remove two mounting bolts to remove plate (25). 2) Remove six mounting bolts to remove cage (26). a Since the inner and outer races of the roller bearing are separated, pull out the cage straight taking care not to pry the races. 3) Remove snap ring (27) and then remove joint (28). 4) Remove 18 mounting bolts to remove cage (29). 5) Remove the outer race of roller bearing (30) from cage (29). a Use a bearing puller to pull out the race. 6) Remove gear (31). a Since the inner and outer races of the roller bearing are separated, pull out the gear straight taking care not to pry the races. 7) Remove the inner races of roller bearings (30) and (32) from gear (31). a Use a bearing puller to pull out the race.

8. Case 1) Remove the outer races of roller bearings (24) and (32) from case (33). a Use a bearing puller to pull out the race. 2) Remove taper roller bearing (34) from case (33). a Use a bearing puller to pull out the bearing. 50-190 Assembly a When installing only the parking brake assembly to the torque converter or the machine, see "Removal and installation of parking brake assembly (installed on the machine)". 1. Case Install the outer races of roller bearings (24) and (32) to case (33). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the case. 2. Input gear 1) Install the inner races of roller bearings (32) and (30) to gear (31). a Using a press, press fit the inner race until its end face comes in contact with the stepped part of the case. 2) Install gear (31). a Since the inner and outer races of the roller bearing are combined together, insert the gear straight taking care not to pry the races. 3) Install the outer race of roller bearing (30) to cage (29). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 4) Install cage (29) by using 18 bolts. a Since the inner and outer races of the roller bearing are combined together, insert the cage straight taking care not to pry the races. 5) Install joint (28) and secure it by using snap ring (27). 6) Install cage (26) with the O-ring by using six bolts. 2 O-ring: Grease (G2-LI) 7) Install plate (25) with the O-ring by using two bolts.

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Power train Disassembly and assembly of transfer

3. Intermediate gear 1) Press fit the inner races of roller bearings (24) and (21) to gear (22). a Using a press, press fit the inner race until its end face comes in contact with the stepped part of the gear. 2) Install joint (23) to gear (22) by using four bolts. 3) Install gear (22). a Since the inner and outer races of the roller bearing are combined together, insert the gear straight taking care not to pry the races. 4) Install the outer race of roller bearing (21) to cage (20). a Using a press, press fit the outer race until its end face comes in contact with the stepped part of the cage. 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 roller 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 1) Install tool D6 to case (33).

5. Parking brake assembly 1) Set parking brake assembly (13) with the O-ring in the installation position, and then tighten the ten bolts partially. 2) Remove two pairs of bolts and washers (12) from parking brake assembly (13). Install parking brake assembly (13) by using a total of 12 bolts. a Loosen the two pairs of bolts and washers slowly and alternately so that the piston inside the parking brake is not pried. 2 Mounting bolt threaded section: Adhesive (LT-2) 3 Mounting bolt: 205.9 to 269.7 Nm {21.0 to 27.5 kgm}

3) Install two plugs (11) to parking brake 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 combination 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 Disassembly and assembly of transfer

6. Rear coupling 1) Install coupling (8). a When the coupling cover was removed, 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. 2 Mounting bolt threaded portion: 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). 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 extra liquid gasket. a Press fit the oil seal until the flange of the tool comes in contact with the cage. 2 Oil seal lip: Grease (G2-LI)

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 using the cage. a Standard thickness of shim pack (reference): 0.8 to 2.0 mm a Available shims: 0.15 and 0.20 mm

3) Fit shim (4) that is selected and install cage (3) by using six bolts. a The shim is 2-piece type. Be sure to install right and left shim packs of same 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 Disassembly and assembly of transfer

8. Front coupling 1) Install coupling (2). 2) Install holder (1) by using tool D7 and bolts. 2 Mounting bolt threaded portion: 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 Disassembly and assembly of parking brake

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-195

Part No.

Part name

SMT-890-1500 Ass'y-Draw 2 SMT-890-1510 q Socket D SMT-890-1520 q Guide 3 SMT-890-1530 q Socket

t t t t

1 1 1 1

Q Q Q Q

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 installed for removing the parking brake assembly. a Loosen the two pairs of bolts and washers slowly and alternately while checking that the piston moves toward the drum. 2) Remove four mounting bolts to remove drum (9). 3) Remove snap ring (10) from drum (9). 6. Piston 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). a Use a bearing puller to pull out. 9. Housing 1) Remove dust seal (18) from housing (19). 2) Remove oil seal (20) from housing (19).

50-195 Assembly 1. Housing 1) Using tool D2, install oil seal (20) to housing (19). a Apply a thin film of liquid gasket (LG-5) to the oil seal press fit surface on the housing. After press fitting the oil seal, wipe off extra liquid gasket. a Press fit the oil seal until the flange of the tool comes in contact with the housing. 2 Oil seal lip: Grease (G2-LI)

2) Use tool D3 to press fit dust seal (18) to housing (19). a Press fit the dust seal until the flange of the tool comes in contact with the housing. 2 Dust seal lip: Grease (G2-LI)

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 Disassembly and assembly of parking brake

a The seal ring has its installed direction. Install the seal ring as shown in the drawing below.

3) Screw two pairs of bolts and washers (8) into the plug holes in the housing. a Use any two pairs of the parking brake mounting bolts and washers. Do no remove them until the parking brake assembly is installed to the transfer. a Screw in the two pairs of bolts and washers 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. a Tighten the bolts evenly and slowly so that the housing does not interfere with the piston.

6. Spacer Install spacer (7). a The spacer also serves as an inner race of 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 Removal and installation of parking brake assembly (installed on the machine)

Preparation of tools

50-198

Removal

50-198

a Prepare tools used for removal and installation. [1] Shackle (2 pcs.) a Shackles not made to the specified dimensions are unusable because they can cause interference.

[2] Guide bolt (3 pcs.)

1. Remove the mounting bolt to remove holder (1). a When loosing the mounting bolt by using a torque multiplier wrench, hold the torque multiplier 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 disconnected. 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 because they are used for securing the parking 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 Removal and installation of parking brake assembly (installed on the machine)

7. Remove the parking brake assembly according to the following procedure. 1) Remove the remaining ten mounting bolts. a Do not remove four hexagonal socket head bolts. 2) Using forcing screws, pull out parking brake assembly (7) toward the rear of the machine to a position where shackles [1] can be installed. 3) Install two shackles [1] in the positions shown in the drawing. 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.

50-19 Installation 1. Install parking brake assembly (7) according to the following procedure and tighten ten mounting bolts partially. 1) Install shackles [1] in the positions shown in the drawing. 2) Sling parking brake assembly (7) from both sides of the transmission and move the parking brake assembly to the transfer side until it connects completely to output shaft (8).

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 Removal and installation of parking brake assembly (installed on the machine)

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 alternately so that the piston inside the parking brake is not pried. 2 Mounting bolt threaded section: 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 multiplier 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 disconnected. 2 Mounting bolt threaded section: 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
Removal 50-201 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the oil from the brake oil tank. 6 Brake oil tank: approx. 315 l 2. Open the upper step cover. 3. Disconnect hoses (1), (2), (3), and (4). Installation
q

50-201
50-201

perform installation in the reverse order to the removal. Pump assembly mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

[*1]

Flushing of brake circuit If the pump is repaired for an internal damage, flush the brake circuit by referring to "Flushing procedure for brake circuit". Refilling with oil (brake oil tank) Refill the brake oil tank with hydraulic oil through the oil filler port to the specified level. 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. Air bleeding Bleed air from the brake hydraulic circuit. For details, see "Bleeding air from the brake hydraulic circuit".

4. Disconnect hoses (5) and (6). 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
Removal 50-202 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil: 2. Open the upper step cover. 3. Disconnect hoses (1) and (2). 4. Disconnect hoses (3), (4), (5) and (6). 5. Remove clamp (7) and disconnect hose (8). 6. Disconnect hose (9). 7. Disconnect suction tube (10).
q q

Installation
q

50-202

perform installation in the reverse order to the removal. Pump assembly mounting bolt: 455 to 565 Nm {46.5 to 58 kgm}

[*1] approx. 1,125 l

q

Flushing hydraulic circuit If the pump is replaced for an internal damage, flush the hydraulic circuit by referring to "Flushing procedure for work equipment and steering hydraulic circuit". Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Air bleeding Bleed air from the piston pump and work equipment hydraulic circuit. For details, see "Bleeding air from piston pump" and "Bleeding air from work equipment hydraulic circuit and steering hydraulic circuit".

8. Sling pump assembly (11), remove mounting bolts, and then remove the pump assembly. [*1] 4 Pump assembly: 250 kg

50-202

WA1200-6

Power train Disassembly and assembly of drive shaft

Disassembly and assembly of drive shaft

Disassembly 50-203 1. Upper drive shaft 1) Remove cover (1) from yoke (2), then remove shaft (3). a Put matchmarks on yoke (2) and shaft (3). 2) Remove retainer (4), seal (5), and cover (1) from shaft (3). 3) Remove mounting bolts (6) from yoke (2) and shaft (3), then remove spider assembly (7). a Put matchmarks on the yoke, shaft, and spider.

50-203

2. Center, front, and rear drive shafts 1) Remove tube (23) from tube (24). a Put matchmarks on tube (23) and tube (24). a When replacing a tube, replace both tubes (23) and (24) at the same time. 2) Remove seal (25) from tube (24). 3) Remove mounting bolts (26) from tubes (23) and (24), then remove spider assembly (27). a Put matchmarks on the tubes and spider. * The drawing shows the center drive shaft.

WA1200-6

50-203

Power train Disassembly and assembly of drive shaft

50-204 Assembly 1. Upper drive shaft 1) Install respective spider assemblies (7) to yoke (2) and shaft (3). a Wipe the bearing cap mounting face by using a clean cloth. a Align the matchmarks accurately. a The phase difference between the right and left spiders must be 3 degrees or less. 3 Mounting bolt: 206 to 221 Nm {21 to 22.5 kgm} 2) Install cover (1), two retainers (4), and seal (5) to shaft (3). 3) Align the matchmarks, then insert shaft (3) into yoke (2) and secure them by using cover (1). a If the spline is worn, replace the drive shaft assembly.

2. Center, front, and rear drive shafts 1) Install respective spider assemblies (27) to tubes (23) and (24). a Wipe the bearing cap mounting face by using a clean cloth. a Align the matchmarks accurately. a The phase difference between the right and left spiders must be 3 degrees or less. 3 Mounting bolt: 337 to 400 Nm {34.4 to 40.8 kgm} 2) Install seal (25) to tube (24). 3) Align the matchmarks, then insert tube (23) into tube (24). a When inserting the tube, take care not to damage the seal. a If the spline is worn, replace the drive 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

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-205

50-205

5. Sling and remove front drive shaft (3). [*2] a Before the removal, put a matchmark on the drive shaft coupling to indicate its installed position. 4 Front drive shaft: 280 kg

Part No.

Part name

1 793T-870-1410 stand 4 SMT-890-5020 Plate

q 1 q 1

Q Q

Removal 50-205 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 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). 4. Sling tire (2) and remove the mounting nuts to remove the right and left tires. [*1] 4 Tire (per tire): 9,150 kg

approx. 45 l 7. Disconnect brake hoses (4), (5) and (6).

6. Drain the oil from the brake tank. 6 Brake oil:

WA1200-6

50-205

Power train Removal and installation of front axle assembly

8. Sling front axle assembly (7), remove 16 mounting bolts (8), and lower the front axle assembly onto the steel plate. [*3] a If the nut turns together with the mounting bolt, use tool L4 (plate). 9. Using a crane or other equipment, pull out the front axle assembly to the outside. 4 Front axle assembly: 16,500 kg

Installation 50-206 q Perform installation in the reverse order to removal. [*1] 3 Tire mounting nut: 1,470 to 1,810 Nm {150 to 185 kgm} [*2] 3 Drive shaft mounting bolt: 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 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 specified level.

50-206

WA1200-6

Power train Removal and installation of front final drive assembly

Removal and installation of front final drive assembly

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-207

50-207

5. Drain the oil from the brake tank. 6 Brake oil:

Part No.

Part name

approx. 45 l 6. Disconnect brake hoses (4), (5) and (6).

1 793T-870-1410 stand 4 SMT-890-5020 Plate SMT-890-5100 Handle assembly SMT-890-5110 q Handle SMT-890-5120 q Flange 04025-00850 q Parallel pin q Hexagon 4 01252-61675 socket head bolt q Hexagon socket head 01252-62045 bolt 01580-31613 q Nut

q q t t t t

1 1 1 1 1 1

Q Q Q Q Q

t 2 t 1 t 1

Removal 50-207 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 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). 4. Sling tire (2) and remove the mounting nuts to remove the right and left tires. [*1] 4 Tire (per tire): 9,150 kg

7. Remove drain plugs (8) of the right and left final cases and drain plug (9) of the differential case to drain oil. [*2] a Take care that the amount of oil to drain is large and the oil spurts out while draining. 6 Axle oil: 670 l

WA1200-6

50-207

Power train Removal and installation of front final drive assembly

8. Remove final case cover (10). [*3] 9. Remove sun gear (11). 10. Sling axle shaft assembly (12) and pull the assembly out of the spline portion of the differential. [*4] a Pull out the shaft assembly on the opposite side in the same way.

50-208 Installation Perform installation in the reverse order to removal. [*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] 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}
q

11. Wrap nylon sling [3] around the final drive assembly. [*4, 5] 4 Final drive assembly: 5,000 kg

Refilling with oil (brake tank) Add oil to the specified level through the oil filler port. 5 Brake oil: approx. 45 l Refilling with oil (axle and final drive) Add oil to the specified level through the oil filler port. 5 Axle oil: 670 l (AXO80) 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 specified level.

50-208

WA1200-6

Power train Removal and installation of rear axle assembly

Removal and installation of rear axle assembly

Special tools
New/redesign Necessity Symbol 3 4 L 5 6 Sketch Q'ty

50-209

50-209

Part No.

Part name

a Use liner plates to adjust the height from the steel plate to the frame to the following values. A = 877 mm, B = 1,527 mm 2. Remove the step cover above the left tire. 3. Sling tire (1) and remove the mounting nuts to remove the right and left tires. [*1] 4 Tire (per tire): 9,150 kg [1] and [2]: Steel plates

793T-870-1420 793T-870-1430 SMT-890-5030 SMT-890-5040 SMT-890-5100 SMT-890-5110 SMT-890-5120 04025-00850

4 01252-61675 01252-62045 01580-31613

stand stand Plate Plate Handle assembly q Handle q Flange q Parallel pin q Hexagon socket head bolt q Hexagon socket head bolt q Nut

q q q q t t t t

1 1 1 1 1 1 1 1

Q Q Q Q Q Q Q

t 2 t 1 t 1

Removal 50-209 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 1. Secure the space for pulling out the rear axle assembly at either side of the machine, and set steel plates and stands according to the following procedure. 1) Place steel plates without gap on the ground below the rear axle assembly on the ground where the removed rear axle assembly is to be placed. 2) Place the machine according to the positions where the stands are to be set.

4. Drain the oil from the brake tank. 6 Brake oil:

approx. 45 l 5. Sling and remove rear drive shaft (2). [*2] a Before the removal, put a matchmark on the rear drive shaft coupling to indicate its installed position. 4 Rear drive shaft: 290 kg

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 Removal and installation of rear axle assembly

6. Disconnect grease hoses (3) and (4) of the axle support.

(Rollers are attached to the bottom of the truck.)

7. Disconnect brake hoses (5), (6) and (7).

(Install the trucks to the right and left ends at the 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 Removal and installation of rear axle assembly

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 Removal and installation of rear axle assembly

50-212 Installation When replacing the axle support bushing, install according to the following procedure. 1. Place rear axle (8) on a flat strand.

2) Apply instantaneous adhesive to the bushing mounting face. 2 Bushing mounting face: 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 metallic objects like scraper on the support mounting face. (Bad example of using scraper)

(Application example)

50-212

WA1200-6

Power train Removal and installation of rear axle assembly

3) Install bushings (11) to the front support. a Bend the bushing inward and install it so that the entire outer periphery of the bushing contacts with the inner face of the support securely according to the drawing below.

4) Install dust seal (12) to retainer (14), and install retainer (14) to the front side of front support (10a). a Install the retainer with the dust seal lip facing outside. 5) Install dust seal (13) to the rear side of front support (10a).

WA1200-6

50-213

Power train Removal and installation of rear axle assembly

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 Removal and installation of rear axle assembly

a Install the dust seal the lip facing outside.

6) Apply grease to the entire inner periphery of bushing (11) and dust seals (12) and (13). 2 Bushing and dust seal: Molybdenum disulphied grease (LM-G)

8) Sling front support assembly (10a) to install to rear axle assembly (8). 4 Front support assembly: 650 kg

7) Apply grease to the outer periphery of the front support mounting face on the rear axle. 2 Outer periphery of the front support mounting face: Molybdenum disulphied grease (LM-G)

a Insert the front support assembly while wobbling its right end.

WA1200-6

50-215

Power train Removal and installation of rear axle assembly

9) Pump grease through grease fitting portion [GF] at the top of the front support assembly. a When inserting the front support assembly, check that a sufficient amount of grease flows out of the gap between the inner periphery of the front support assembly and the rear axle portion.

3. Rear support 1) Install bushings (11) and dust seals (13) to rear support (10b) according to the same procedure as to front support (10a).

a Pump grease until it flows out as shown in the drawing below.

50-216

WA1200-6

Power train Removal and installation of rear axle assembly

a Install the dust seal with the lip facing outside.

2) Apply grease to the entire inner periphery of bushings (11) and dust seal (13). 2 Bushing and dust seal: Molybdenum disulphied grease (LM-G)

4) Sling rear support assembly (10b) to install to rear axle assembly (8). a Insert the rear support assembly while wobbling its right end vertically. 4 Rear support assembly: 960 kg

3) Apply grease to the outer periphery of the rear support mounting face on the rear axle. 2 Outer periphery of rear support mounting face: Molybdenum disulphied grease (LM-G)

5) Set thrust washer (16) to the inside of thrust plate (15), and install them to rear axle (8). 4 Thrust plate: 100 kg 3 Mounting bolt: 2,450 to 3,040 Nm {250 to 310 kgm}

WA1200-6

50-217

Power train Removal and installation of rear axle assembly

a When reusing the mounting bolt, apply seizure prevention compound to the threaded portion. 2 Mounting bolt: Seizure prevention compound (LC-G)

7) Set the thrust washer to the rear support assembly. 4 Thrust washer: 100 kg 8) Install cover (18) to rear support assembly (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 Removal and installation of rear axle assembly

9) Pump grease through the rear breather mounting hole. Pump grease through the grease filling nipple mounting hole (D) at the top of the rear support. a Pump grease until it flows out from the grease filling nipple mounting hole (P) at the top of the rear support and dust seal portion (Q).

Perform the subsequent installation in the reverse order to removal. [*1] 3 Tire mounting nut: 1,470 to 1,810 Nm {150 to 185 kgm} [*2] 3 Drive shaft mounting bolt: 343 to 427 Nm {35 to 43.5 kgm} [*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}
q q

Refilling with oil (brake tank) Add oil to the specified level through the oil filler port. 5 Brake oil: approx. 45 l 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 specified level.

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Power train Removal and installation of rear final drive assembly

Removal and installation of rear final drive assembly

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-2 0

50-2 0

2. Drain the oil from the brake tank. 6 Brake oil:

Part No.

Part name

approx. 45 l 3. Sling tire (1) of the final drive to be removed. 4. Remove the mounting nuts to remove the right or left tire. [*1] 4 Tire (per tire): 9,150 kg 5. Disconnect brake hoses (5), (6) and (7).

3 793T-870-1420 stand L 4 793T-870-1430 stand SMT-890-5100 Handle assembly SMT-890-5110 q Handle SMT-890-5120 q Flange 04025-00850 q Parallel pin q Hexagon J 4 01252-61675 socket head bolt q Hexagon socket head 01252-62045 bolt 01580-31613 q Nut

t t t t t t

1 1 1 1 1 1

Q Q Q Q Q

t 2 t 1 t 1

Removal 50-2 0 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 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 where the stands are to be set. 2) Place the machine according to the positions 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 a Use liner plates to adjust the height from the steel plate to the frame to the following values. A = 887 mm, B = 1,527 mm

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Power train Removal and installation of rear final drive assembly

6. Remove drain plugs (8) of the right and left final cases and drain plug (9) of the differential case to drain oil. [*2] a Take care that the amount of oil to drain is large and the oil spurts out while draining. 6 Axle oil: 670 l

7. Remove final case cover (10). 8. Remove sun gear (11).

[*3]

9. Sling axle shaft assembly (12) and pull the assembly out of the spline portion of the differential. [*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

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Power train Removal and installation of rear final drive assembly

50-2 2 Installation a Do not reuse kit parts shown in the installation procedure, but replace with new ones. q Perform installation in the reverse order to removal. [*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] 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}
q

Refilling with oil (brake tank) Add oil to the specified level through the oil filler port. 5 Brake oil: approx. 45 l Refilling with oil (axle and final drive) Add oil to the specified level through the oil filler port. 5 Axle oil: 670 l (AXO80) 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 specified level.

50-222

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Power train Removal and installation of differential assembly

Removal and installation of differential assembly

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-2 3

50-2 3

Part No.

Part name

SMT-890-5100 Handle assembly SMT-890-5110 q Handle SMT-890-5120 q Flange 04025-00850 q Parallel pin q Hexagon 4 01252-61675 socket head bolt q Hexagon 01252-62045 socket head bolt 01580-31613 q Nut

t t t t

1 1 1 1

Q Q Q

2. Remove drain plugs (2) of the right and left final cases and drain plug (3) of the differential case to drain oil. [*1] a Take care that the amount of oil to drain is large and the oil spurts out while draining. 6 Axle oil: 670 l

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Removal 50-2 3 1. Remove axle assembly (1) and set it on wooden blocks [1]. For details, see "Removal and installation 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 differential. [*3] a Pull out the shaft assembly on the opposite side in the same way.

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Power train Removal and installation of differential assembly

6. Remove speed sensor (7). a Front axle only

[*4]

7. Remove mounting bolts (8) and remove differential assembly (9). [*5] a Mounting bolt of different dimensions are used. Note the installed positions of bolts.

50-2 4 Installation q Perform installation in the reverse order to removal. [*1] 3 Drain plug (2): 127 to 176 Nm {13 to 18 kgm} 3 Drain plug (3): 127 to 176 Nm {13 to 18 kgm} [*2] 3 Mounting bolt: 245 to 309 Nm {25 to 31.5 kgm} [*3] Use tool J4 to insert the axle shaft assembly. [*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}

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Power train Disassembly and assembly of differential

Disassembly and assembly of differential

Front differential

50-2 5
50-2 5

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Power train Disassembly and assembly of differential

Rear differential

50-2 6

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Power train Disassembly and assembly of differential

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-2 7

Part No.

Part name

792-340-1120 796-550-1310 792-525-3000 J 2 790-425-1670 790-425-1660 1

Nut wrench Wrench Micrometer Adapter Wrench

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1 1 1 1 1

Disassembly 50-2 7 1. Cover Remove two mounting bolts to remove cover (8). a Front differential only 2. Flange Remove snap ring (9), then remove flange (10). a Front differential only 3. Lock plate Remove four mounting bolts, and remove two lock plates (11). a After removing the lock plate, mark the lock position on the adjustment nut (26). 4. Cage assembly Front differential 1) Remove two mounting bolts and bracket (12). 2) Remove 22 mounting bolts and cage assembly (13). 3) Remove shim (14) from cage (15). a Note the number and thickness of the shims for installation purpose. 4) Remove the mounting bolts, then remove holder (16) and shim (17). a Note the number and thickness of the shims for installation purpose. 5) Remove coupling (18). 6) Remove four mounting bolts to remove cage (19).

7) Remove dust seal (20) from cage (19). 8) Remove oil seal (21) from cage (19). 9) Using a press, remove pinion (22) and the inner race of bearing (24) as a unit from cage (15). 10)Remove the inner race of roller bearing (23) from cage (15). 11)Remove the inner race of roller bearing (24) from pinion (22). a Use a press to pull out. 12)Remove the outer races of roller bearings (23) and (24) from cage (15). a Use a bearing puller to pull out. Rear differential 1) Remove 24 mounting bolts to remove cage assembly (13). 2) Remove shim (14) from cage (15). a Note the number and thickness of the shims for installation purpose. 3) Remove the mounting bolts, then remove holder (16) and shim (17). a Note the number and thickness of the shims for installation purpose. 4) Remove coupling (18). 5) Remove eight mounting bolts to remove support (15A). 6) Remove four mounting bolts to remove cage (19). 7) Remove dust seal (20) from cage (19). 8) Remove oil seal (21) from cage (19). 9) Using a press, remove pinion (22) and the inner race of bearing (24) as a unit from cage (15). 10)Remove the inner race of roller bearing (23) from cage (15). 11)Remove the inner race of roller bearing (24) from pinion (22). a Use a press to pull out. 12)Remove the outer races of roller bearings (23) and (24) from cage (15). a Use a bearing puller to pull out.

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Power train Disassembly and assembly of differential

5. Differential gear assembly 1) Remove four mounting bolts, and remove two caps (25). a Separate the right and left caps. 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 removing. 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 a unit. 7) Remove four pinion gear assembly (34) from spider shaft (33). 8) Disassemble pinion gear assembly (34) according to the following procedure. 1] Secure pinion gear assembly (34) with a press, and remove lock nut (35) with wrench J1. 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).

5] Using a press, remove outer race (38D) from pinion gear (36). 6] Using a press, remove collar (38E) and outer race (38F) from pinion gear (36).

9) Remove side gear (39). 10)Remove the inner race of bearing (27) and thrust washer (40) from case (41). 11)Remove tube (42) and remove two bushings (43). a Front differential only 12)Remove 20 bolts to remove bevel gear (44). a Make matchmarks on the bevel gear and case before removing.

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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 figure.

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). 6) Assemble pinion gear (34) according to the following procedure. 1] Using a press, install collar (38E) and outer race (38F) to pinion gear (36). 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.

7) Install spider shaft (33) with four pinion gear assemblies (34) to case (41). 8) Install side gear (32). a Move the side gear to check that the pinion gears rotate smoothly.

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Power train Disassembly and assembly of differential

9) Install the inner race of bearing (27) and thrust washer (31) to case (30). a When installing the right and left bearings, check the identification mark put on the right and left inner races to prevent wrong installation. 2 Contact surfaces on thrust washer (31) and side gear (32): 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 bearings, 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).

14)Install two caps (25) to carrier (29) with four bolts. a Check that right and left caps are on the correct sides. a Tighten the bolts after rotating the bevel gear 20 to 30 turns to run in the bearing. 3 Mounting bolt: 1,520 to 1,910 Nm {155 to 195 kgm}

13)Tighten two nuts (26) to carrier (29) partially. a Check that the carrier rotates smoothly by hand.

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 (micrometer) 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 the standard range. Also, rotate bearing (27) until the full contact of the bearing 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}

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Power train Disassembly and assembly of differential

a Precautions when adjusting preload If the deflection should exceed the standard dimension due to overtightening of the adjustment nut, return the nut to the position before the adjustment. To do this, lightly hit the bearing cap and bevel gear with a plastic hammer, etc. while rotating the bevel gear. Make sure that no clearance exists in the nut and bearing portions and then make adjustment again.

2. Cage assembly Front differential 1) Install the outer races of roller bearings (23) and (24) to cage (15). a Press fit the outer race until its end face comes in contact with the stepped part of the cage. 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. 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 using 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.

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Power train Disassembly and assembly of differential

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 differential carrier according to the following procedure. a If the bearing, pinion gear, bevel gear, etc. is replaced, perform the shim adjustment procedure. 1] Measure distance "a" from carrier (29) to pinion gear (22).

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Power train Disassembly and assembly of differential

2] Calculate reference value "b". q b = (427 + c) - (121.69 + d) mm a Dimension "c" and dimension "d" are indicated at the tip of the pinion shaft in icrements of 1/100 mm. (Be careful with the plus and minus signs.)

Rear differential 1) Install the outer races of roller bearings (23) and (24) to cage (15). a Press fit the outer race until its end face comes in contact with the stepped part of the cage. 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.

3] Calculate necessary shim pack thickness "e". q e = b- a a Available shims: 0.2, 0.3, and 1.0 mm a Obtain the necessary thickness by using a minimum number of shims. 14)Fit selected shims (14), and install cage (15) to cage (29) with 22 bolts. 3 Mounting bolt: 1,520 to 1,910 Nm {155 to 195 kgm} 15)Install bracket (12) to cage (15) with two bolts. 3 Mounting bolt: 1,520 to 1,910 Nm {155 to 195 kgm}

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.

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Power train Disassembly and assembly of differential

4) Install the inner race of roller bearing (23) to pinion (22).

a If it is outside the range, adjust the shims again.

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.

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)

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 using 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}.

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Power train Disassembly and assembly of differential

9) Install cage (19) to cage (15) with four bolts. 3 Mounting bolt: 157 to 196 Nm {16 to 20 kgm}

13)Install the O-ring to cage (15). 14)Adjust the shim pack thickness of the differential carrier according to the following procedure. a If the bearing, pinion gear, bevel gear, etc. is replaced, perform the shim adjustment 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) 12)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}

2] Calculate reference value "b". q b =(427 + c) - (121.69 + d) mm a Dimension "c" and dimension "d" are indicated at the tip of the pinion shaft in increments of 1/100 mm. (Be careful with the plus and minus signs.)

3] Calculate necessary shim pack thickness "e". q e =b - a a Available shims: 0.2, 0.3, and 1.0 mm a Obtain the necessary thickness by using a minimum number of shims.

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Power train Disassembly and assembly of differential

15)Fit selected shims (14), and install cage (15) to cage (29) with 24 bolts. 3 Mounting bolt: 1,520 to 1,910 Nm {155 to 195 kgm} 3. Adjust the bevel pinion backlash according to the following procedure. a Use the adjustment nuts to move the bevel gear. Turn the nuts on both sides by the same angle in the same direction so that the preload of the bearing does not change. 1] Attach dial gauge J2 to the outer end of the bevel gear. 2] Adjust the backlash with the adjustment nuts so that the backlash is within the specified range. a Backlash: 0.43 to 0.61 mm a Measure the backlash at three to four places with the pinion gear locked. 4. Coat the bevel gear tooth surface slightly with red lead, then check the tooth contact. a Turn the bevel gear, and check that the contact pattern on the concave and convex surfaces are within the range specified in the drawing below.

1) If proper tooth contact pattern is not obtained upon checking, perform tooth contact adjustment. a Tooth contact adjustment is performed by moving the bevel gear and increasing or decreasing the shims of the cage assembly (to move the bevel pinion). a After adjusting the tooth contact, check the backlash again. a When adjusting the bevel gear position to the right or left, turn both right and left adjustment nuts to the same direction by the same amount (check by the shifting of the notch) so that the preload of the bearing is not changed. a Available shims: 0.2, 0.3, and 1.0 mm 2) If the bevel pinion is too far from the bevel gear, the tooth contact pattern is as shown in the following figure. Make a correction according to the following procedure. q Decrease the shims of the cage assembly (on the bevel pinion side) to move the bevel pinion in the direction of C. q Adjust the bearing adjustment nut to move the bevel gear in the direction of D away from the bevel pinion.

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Power train Disassembly and assembly of differential

3) If the bevel pinion is too close to the bevel gear, the tooth contact pattern is as shown in the following figure. Make a correction according to the following procedure. q Increase the shims of the cage assembly (on the bevel pinion side) to move the bevel pinion in the direction of E. q Adjust the bearing adjustment nut to move the bevel gear in the direction of F closer to the bevel pinion.

5) If the bevel gear is too far from the bevel pinion, the toorh contact pattern is as shown in the following figure. Make correction according to the following procedure: q Increase the shims of the cage assembly (on the bevel pinion side) to move the bevel pinion in the direction of E. q Adjust the bearing adjustment nut to move the bevel gear in the direction of F closer to the bevel pinion.

4) If the bevel gear is too close to the bevel pinion, the tooth contact pattern is as shown in the following figure. Make correction according to the following procedure. q Decrease the shims of the cage assembly (on the bevel pinion side) to move the bevel pinion in the direction of C. q Adjust the bearing adjustment nut to move the bevel gear in the direction of D away from the bevel pinion.

5. Lock plate Install two lock plates (11) with four bolts. 3 Mounting bolt: 245 to 309 Nm {25 to 31.5 kgm} 6. Flange Install flange (10) and install snap ring (9). a Front differential only 7. Cover Install cover (8) with two bolts. a Front differential only 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm} 2 Mounting bolt: Adhesive (LT2)

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Power train Disassembly and assembly of final drive and brake

Disassembly and assembly of final drive and brake

50-238

50-238

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Power train Disassembly and assembly of final drive and brake

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Power train Disassembly and assembly of final drive and brake

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-240

Part No.

Part name

SMT-890-3100 Tool assembly SMT-890-3110 q Cylinder 3 SMT-890-3120 q Piston SMT-890-3130 q Shaft SMT-890-3140 q Plate 5 SMT-890-1910 Installer

t t t t t t

1 1 1 1 1 1

Q Q Q Q Q Q

6. Carrier assembly (small) 1) Remove carrier assembly (22). 2) Remove spacer (24) from carrier (23). 3) Remove snap ring (25), then remove pin (26). a Remove three sets. 4) Remove three balls (27). 5) Remove three gears (28) from carrier (23). 6) Remove two bearings (29) and remove spacer (30). a Remove three sets. 7) Remove snap ring (31) from gear (28). a Remove three sets. 7. Hub and brake assembly 1) Sling hub and brake assembly (32), remove 36 mounting bolts to remove assembly (32). 2) Remove the O-ring and remove plate (33). 8. Hub ring gear assembly 1) Remove eight mounting bolts, and then remove retainer (34) and shims (35). a Note the number and thickness of the shims for installation purpose. 2) Remove hub ring gear assembly (36). 3) Remove the O-ring from tube (74). 4) Remove two mounting bolts, and remove two plates (37). 5) Remove retainer (38) and remove the O-ring. 6) Remove floating seal (39) and remove the O-ring. 7) Remove ball (40). 8) Remove the inner race of roller bearing (41) from hub (42). 9) Remove 16 mounting bolts, and remove eight plates (43). 10)Remove ring gear (44) from hub (42). 9. Wheel hub assembly 1) Remove 61 stud bolts (45) from wheel hub assembly (46). 2) Remove the outer race of roller bearing (41) from hub (51). 3) Remove floating seal (47) and remove the O-ring. 4) Remove retainer (48) and remove floating seal (49). 5) Remove the O-ring from floating seal (49). 6) Remove the O-ring from hub (51). 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).

Disassembly 50-240 1. Cover assembly 1) Remove 16 mounting bolts to remove cover assembly (3). 2) Remove the O-ring from cover (4). 3) Remove spacer (5). 4) Remove three mounting bolts to remove shaft (6). 2. Sun gear Remove gear (7). 3. Carrier assembly (large) 1) Remove four cap bolts, and remove carrier assembly (8). 2) Remove the O-ring from carrier assembly (8). 3) Remove four shafts (10) from carrier (9), and remove four balls (11). a Remove four sets. 4) Remove four gears (12) from carrier (9). a Remove four sets. 5) Remove bearing (13) from gear (12). a Remove four sets. 6) Remove snap ring (14) from gear (12). a Remove four sets. 4. Ring gear 1) Remove 16 mounting bolts, and remove eight plates (15). 2) Remove ring gear (16). 5. Shaft assembly 1) Remove shaft assembly (17). 2) Remove snap ring (21) and gear (19). 3) Remove spacer (20) from shaft (18).

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Power train Disassembly and assembly of final drive and brake

4) 5) 6) 7) 8) 9)

Remove the O-ring from floating seal (54). Remove plug (55) and remove the O-ring. Remove bleeder (56). Remove plug (57) and remove the O-ring. Remove three plugs (58). 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) alternately. 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).

Assembly 1. Tube 1) Install retainer (72) to tube (74).

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2) Install three washers (73) to tube (74), and drive in the dowel pin.

3) Press fit the inner race of roller bearing (50) to tube (74). a Shrink fit the inner race for press fit (approx. 60 C).

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Power train Disassembly and assembly of final drive and brake

2. Gear 1) Install inner gear (71) to tube (74).

3. Disc wear indicator 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}

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Power train Disassembly and assembly of final drive and brake

4. Discs and plates 1) Install ten plates (68) and nine discs (69) alternately. a Install the nine plates on the tube side aligning their tooth-missing parts with the disc wear indicator installation position. a Install the one plate on the piston side so that it's tooth contacts with the disc wear indicator.

5. Wheel hub assembly 1) Press fit the outer race of roller bearing (50) to hub (51). a Expand fit the outer race for press fit (cool for 30 minutes with dry ice). a Press fit the outer race until its end face comes in contact with the hub.

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).

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Power train Disassembly and assembly of final drive and brake

4) Install the floating seal to the retainer according to the following procedure. 1] Install O-ring (49a) of the floating seal to 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.

4] Place floating seal (49) on O-ring (49a). 2 Floating seal: Brake cooling oil (TO10)

2] After installing O-ring (49a), to check for twist of the O-ring, put marking "b" with a 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)

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. a Markings (b) on the entire periphery must be visible uniformly.

Be careful not to let your fingers caught while pushing the O-ring (49a) to floating seal (49) with finger.

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Power train Disassembly and assembly of final drive and brake

a After installation, measure dimension "a" at four places on the periphery, and check that its dispersion is 1 mm or less.

5) Reverse hub (51) and press fit the outer race of roller bearing (41). a Expand fit the outer race for press fit (cool for 30 minutes with dry ice). a Press fit the outer race until its end face comes in contact with the hub.

6) Install O-ring (47a) to floating seal (47). 2 Floating seal: Brake cooling oil (TO10) 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: Brake cooling oil (TO10) 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 periphery, and check that its dispersion is 1 mm or less. (Similarly to floating seal (49).) 8) Install 61 stud bolts (45) to hub (51). a Screw in the stud bolt up to the incomplete thread portion. a Check that each stud bolt has the identification mark. a Screw-in dimension (reference): 139 mm 3 Stud bolt: 441 to 883 Nm {45 to 90 kgm}

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Power train Disassembly and assembly of final drive and brake

6. Hub ring gear assembly 1) Press fit the inner race of roller bearing (41) to hub (42). 2) Install ring gear (44) to hub (42). 3) Install eight plates (43) with 16 bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 to 309 Nm {25 to 31.5 kgm} 4) Install ball (40). 5) Install the O-ring to retainer (38). 6) Install retainer (38) to hub (42). 2 Retainer mounting portion: Grease (G2-LI) 7) Install two plates (37) with two bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm} 8) Install the O-ring to floating seal (39). 2 Floating seal: Brake cooling oil (TO10) 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: Brake cooling oil (TO10) 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. (Similarly to floating seal (49).)

7. Adjusting preload of wheel bearing 1) Install wheel hub assembly (46) and hub ring gear assembly (36) to tube (74). 2 Bearing: Axle oil (AXO80) 2) Install preload adjustment jig J3 with three bolts. 3) While checking with oil pressure gauge [2], operate the hydraulic pump to apply the following specified hydraulic pressure to preload adjustment jig J3. a Specified pressure: 39.2 MPa 2 {400 kg/cm } 4) Close needle valve [3], and remove the coupler. 5) Turn the hub wheel assembly fully to fit in the bearing. a Check that the pressure is 37.3 MPa {380 kg/cm2} or more. If the pressure drops, apply the pressure again according to Step 3).

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Power train Disassembly and assembly of final drive and brake

6) Using a micro gauge, measure dimensions "a" and "c" of the jig. 7) Using the depth micro gauge, measure dimension "b" between the cylinder upper surface and the piston upper surface. a Measure the distances at three places and obtain the average. 8) Calculate necessary shim pack thickness "d". 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.

8. Cylinder and piston assembly 1) Install seals (67) and (66) to piston (65). a Install O-rings (67a) and (66a) first, then install seals (67) and (66). a Before installing the seal, check that the piston groove is free from damage or foreign objects. 2 Seal periphery: Grease (G2-LI)

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)

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Power train Disassembly and assembly of final drive and brake

3) Install eight springs (64) and eight guides (61).

13)Install plug (55) with the O-ring to cylinder (52). 3 Plug: 34.3 to 44.1 Nm {3.5 to 4.5 kgm} 14)Check the brake seal according to the following procedure. 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).

6) Install the O-ring to cylinder (52). 7) Install cylinder (52) to gear (75) with 16 bolts. 3 Mounting bolt: 824 to 1,030 Nm {84 to 105 kgm} 8) Install two O-rings, and install two plugs (60) to cylinder (52). 3 Plug: 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: Liquid gasket (LG-5)

15)Adjust the disc wear indicator according to the following procedure. 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 the guide with nut. 3 Nut: 237.7 to 321 Nm {24 to 33 kgm} 3] Install cap (81) to guide (82). 3 Cap: 117.6 to 161.7 Nm {12 to 16.5 kgm}

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Power train Disassembly and assembly of final drive and brake

16)Referring to Step 4) of See "5. Wheel hub assembly". install floating seal (54) to cylinder (52). 17)Install oil seal (53) to cylinder (52). 2 Oil seal press fit portion: LOCTITE 648 2 Oil seal lip: Grease (G2-LI) 9. Wheel hub assembly and hub ring gear assembly 1) Install wheel hub assembly (46). 2 Bearing: Axle oil (AXO80) 2) Install hub ring gear assembly (36). 2 Bearing: Axle oil (AXO80) 3) Fit selected shims (35) and retainer (34) with eight bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 1,520 to 1,910 Nm {155 to 195 kgm} 10. Hub and brake assembly 1) Install plate (33) with the O-ring to tube (74). 2) Install hub and brake assembly (32) with 36 mounting bolts. 3 Mounting bolt: 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).

12. Shaft assembly 1) Install spacer (20) to shaft (18). 2) Install gear (19) to shaft (18), and install snap ring (21). 3) Install shaft assembly (17). 13. Ring gear 1) Install ring gear (16) to ring gear (44). 2) Install eight lock plates (15) with 16 bolts. 2 Mounting bolt: Adhesive (LT-2) 3 Mounting bolt: 245 to 309 Nm {25 to 31.5 kgm} 14. Carrier assembly (large) 1) Install snap ring (14) to gear (12). a Install four sets. 2) Install bearing (13) to gear (12). a Install four sets. 3) Install four gears (12) to carrier (9) with four balls (11) and four shafts (10). 4) Fit the O-ring to carrier assembly (8), and install the assembly with four cap bolts. 3 Mounting bolt: 123 to 157 Nm {12.5 to 16 kgm} a When installing the carrier assembly to the hub, align drilled hole "b" under the drain plug of the carrier with through tap hole "a" of the hub.

WA1200-6

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Power train Disassembly and assembly of final drive and brake

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

Removal 50-251 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drive shaft 1) Sling center drive shaft (1) and remove it. [*1] 4 Center drive shaft: 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. 4 Front drive shaft: 280 kg

50-251

2. Center support 1) Sling center support (3), remove the mounting bolts, and then remove the center support. [*3] a Take care not to damage the steering cylinder rod when removing the center support. 4 Center support assembly: 164 kg

WA1200-6

50-251

Power train Removal and installation of center support assembly

50-252 Installation Perform installation in the reverse order to removal. [*1] 3 Center drive shaft: 343 to 427 Nm {35 to 43.5 kgm} [*2] 3 Front drive shaft: 343 to 427 Nm {35 to 43.5 kgm} [*3] a When installing the center support, shim adjustment is unnecessary. 3 Center support mounting bolt: 824 to 1,030 Nm {84 to 105 kgm}

50-252

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Power train Disassembly and assembly of center support

Disassembly and assembly of center support

Disassembly 1. Retainer Remove three mounting bolts (2) of retainer (1).

50-253

50-253 3. Retainer 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), coupling (5) and shim (6). a Note the thickness and quantity of the shims.

4. Shaft 1) Set the shaft and housing assembly (8) on the press stand. 2) Push out shaft (9) using the press. a Take care not drop the shaft to the floor directly.

WA1200-6

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Power train Disassembly and assembly of center support

3) Remove bearing (10) and retainer (1) from the shaft.

50-254 Assembly 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 retainer. q Reference dimension (a) = 2 0.5 mm 2 Oil seal lip: Grease (G2-LI)

6. Housing Remove outer races (12) from the housing.

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Power train Disassembly and assembly of center support

3. Shaft 1) Install retainer (1) to the shaft. 2) Using a push tool, install bearing (10) to shaft (9).

4. Retainer 1) Install retainer (7). a Fill inner space (c) with grease (G2-LI). 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). 4) Tighten mounting bolts (2) of retainer (1). 3 Mounting bolt: 98 to 123 Nm {10.0 to 12.5 kgm} 5) Using a push tool, install bearing (14).

5. Shim adjustment 1) Install coupling (5), holder (4) and bolt (3).

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}

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Power train Disassembly and assembly of center support

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)

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Steering system Removal and installation of steering demand valve assembly

Steering system

Removal and installation of steering demand valve assembly

Removal 50-257 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil: 2. Disconnect tubes (1) and (2). 3. Disconnect hoses (3), (4), and (5). 4. Remove U-bolts and disconnect tubes (6), (7), and (8).
q

50-257
50-257

50-257

Installation
q

perform installation in the reverse order to the removal. Valve assembly mounting bolt: 235 to 285 Nm {23.5 to 29.5 kgm}

[*1] approx. 1,125 l

q

Refilling with oil (hydraulic tank) Refill the hydraulic tank with oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Air bleeding Bleed air from the piston pump and work equipment hydraulic circuit. For details, see "Bleeding air from piston pump" and "Bleeding air from work equipment hydraulic circuit and steering hydraulic circuit".

5. Sling steering demand valve assembly (9), remove three mounting bolts (10), and then remove the steering demand valve assembly together with the bracket. [*1] 4 Steering demand valve assembly: 70 kg a The above removal procedure is described based on the right steering demand valve assembly. The left steering demand valve assembly is removed in the similar way.

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50-257

Steering system Removal and installation of steering cylinder assembly

Removal and installation of steering cylinder assembly

Removal 50-258 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 1. Disconnect grease hose (1) and remove the nipple.

50-258

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 procedure. 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). a Thread diameter: 24 x 3 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 forcing 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

5. Disconnect grease hose (11) and remove the nipple.

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Steering system Removal and installation of steering cylinder assembly

6. Sling steering cylinder assembly (12). 7. Remove the steering cylinder pin (on the cylinder bottom side) according to the following procedure. 1) Remove four upper mounting bolts (13) and six retainer lock bolts (13a) of pin (8a). k Pin (8a) may come off when you remove the bolts. Be sure to support the 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). 6) Remove plate (16) and bushing (18). 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 removed. 4 Steering cylinder pin: 50 kg 8. Sling and remove steering cylinder assembly (12) while moving it backward. 4 Steering cylinder assembly: 590 kg

Installation 50-259 perform installation in the reverse order to removal. Flushing of hydraulic circuits When repairing the steering cylinder that is internally damaged, perform flushing of hydraulic circuits. For details, see "Flushing procedure for work equipment and steering circuit".

WA1200-6

50-259

Steering system Removal and installation of steering cylinder assembly

Install the steering cylinder pin (on the cylinder bottom side) according to the following procedure. a Completely wipe off grease and lubricant adhered to periphery of pin, inner surface of bushing (a), and taper surface of taper bushing (b). a When installing the steering cylinder pin, be careful not to put grease and lubricant on periphery 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 bottom. 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. a Install the bushings so that their mating 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}

9) Tighten the lower four mounting bolts (15) to the specified torque. a Be sure to tighten the upper mounting bolts to the specified torque first, then tighten the lower mounting bolts to the specified torque. 3 Mounting bolt: 824 to 1,030 Nm {84 to 105 kgm}

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WA1200-6

Steering system Removal and installation of steering cylinder assembly

Install the steering cylinder pin (on the rear frame side) according to the following procedure. a Completely wipe off grease and lubricant adhered to periphery of pin, inner surface of piston rod bushing (a), and taper surface of taper bushing (b). a When installing the steering cylinder pin, be careful not to put grease and lubricant on periphery of pin, inner surface of piston rod bushing (a), and taper surface of taper bushing (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. k Be sure to support the pin at the bottom. 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). a Install the bushings so that their mating faces (d) are in the horizontal direction. 4) Remove two eyebolts. 5) Install retainer (3) and partially tighten six 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. a Install the bushings so that their mating 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 specified torque. 3 Mounting bolt: 824 to 1,030 Nm {84 to 105 kgm}

8) Tighten the lower four mounting bolts (4) to the specified torque. a Be sure to tighten the upper mounting bolts to the specified torque first, then tighten the lower bolts to the specified torque. 3 Mounting bolt: 824 to 1,030 Nm {84 to 105 kgm}

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50-261

Steering system Removal and installation of emergency diverter valve assembly

Removal and installation of emergency diverter valve assembly

Removal 50-262 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil:

50-262

3. Removal of the diverter valve assembly (lower). 1) Disconnect harness connector R11 (8).

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 q Perform installation in the reverse order to removal.

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". Refilling with oil (hydraulic tank) Supply 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. Air bleeding Bleed air from the piston pump and work equipment circuit. For details, see "Bleeding air from piston pump" and "Bleeding air from work equipment 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

Removal 50-264 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil: 2. 3. 4. 5.

50-264

50-264 Installation q perform installation in the reverse order to removal. [*1]

3

approx. 1,125 l Disconnect hose (1). Disconnect hose (2). Disconnect hose (3). Sling emergency steering pump assembly (4), remove mounting bolts, and remove the assembly. [*1] a Take the same procedure to remove the lower emergency steering pump assembly. 4 Emergency steering pump assembly (1 unit): 50 kg

Pump assembly mounting bolt: 245 to 309 Nm {25 to 31.5 kgm}

Flushing of hydraulic circuits When repairing the pump that is internally damaged, perform flushing of hydraulic circuits. For details, see "Flushing procedure for work equipment and steering circuit". Refilling with oil (hydraulic tank) Supply 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. Air bleeding Bleed air from the piston pump and work equipment circuit. For details, see "Bleeding air from piston pump" and "Bleeding air from work equipment circuit and steering circuit".

50-264

WA1200-6

Brake system Removal and installation of brake accumulator charge valve assembly

Brake system

Removal and installation of brake accumulator charge valve assembly 50-265

Removal 50-265 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Remove brake oil tank return tube (T) (1). Installation
q

50-265
50-265

perform installation in the reverse order to the removal. 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 accumulator. 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

Removal 50-26 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 1. Drain the oil from the brake tank. 6 Brake tank:
q

50-26

50-26 Installation Perform installation in the reverse order to removal. [*1] 3 Brake oil tank mounting bolt: 824 to 1,030 Nm {84 to 105 kgm} Refilling with oil (brake oil tank) Refill hydraulic oil through the oil filler port to the specified level. Air bleeding Bleed the air from the brake circuit. For details, see "Bleeding air from brake circuit".

approx. 105 l 2. Disconnect the level sensor harness connectors HR6 and HR10 (1) of the brake oil tank.

3. 4. 5. 6. 7. 8.

Disconnect brake suction tube (2). Disconnect brake return tube (3). Disconnect brake cooler suction tube (4). Disconnect brake cooler return tube (5). Disconnect drain hose (6). Sling brake oil tank assembly (7), remove mounting bolts (8), and remove the assembly. [*1] 4 Brake oil tank assembly: 225 kg

50-266

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Undercarriage and frame Procedure for disconnecting front frame and rear frame

Undercarriage and frame

Procedure for disconnecting front frame and rear frame

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. a Use truck (3) for 100-ton load.

50-267

50-267

8. Remove parts to be replaced from the frame and 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 adjustment, see "Removal and installation of center hinge pin". Shape of truck [Example] q (4): Four track rollers of PC800

After setting the truck under the front frame, be sure to implement "2. Preparatory 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).

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50-267

Undercarriage and frame Removal and installation of center hinge pin

Removal and installation of center hinge pin

Special tools
New/redesign Necessity Symbol Sketch Q'ty

50-268

50-268

Part No.

Part name

Removal 50-268 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work" in "00 Safety notice". 1. Work equipment assembly Remove the work equipment assembly. For details, see "Removal and installation of work equipment assembly". 2. Operator's cab and floor assemblies Remove the operator's cab and floor assembly. For details, see "Removal and installation of operator's cab and floor assembly". 3. Steering cylinder pin (on the rear frame side) 1) Remove four upper mounting bolts (5) and six retainer lock bolts (6) of pin (1). k Pin (1) may come off when the bolts are removed. Be sure to support the pin at the bottom. 2) Remove retainer (7). 3) Install eyebolts into two pin bolt holes (at the diagonal positions) and sling pin (1). a Thread diameter: 24 x 3 Stem length: 77 mm (threaded portion length: 43 mm) 4) Remove bushing (8). 5) Remove four lower mounting bolts (2) of pin (1). 6) Remove plate (3) and bushing (4). 7) Sling pin (1) and remove it. 4 Steering cylinder pin: 50 kg

790-314-1000 790-101-40000 790-101-1102 SMT-890-2100 SMT-890-2110 SMT-890-2120 SMT-890-2150 SMT-890-2160 SMT-890-2170 1 SMT-890-2180 01643-33690 01580-03629 SMT-890-2130 SMT-890-2140 SMT-890-2210 SMT-890-2220 791-775-1140 K 01643-33080 01582-03024 2 790-101-4000 790-101-1102 SMT-890-2300 SMT-890-2310 SMT-890-2320 SMT-890-2330 SMT-890-2210 SMT-890-2220 791-775-1140 01643-33080 01532-03034 SMT-890-2410 SMT-890-2420 3 SMT-890-2430 SMT-890-2440

Puller Puller Pump Push tool q Guide q Guide q Guide q Guide q Plate q Bolt q Washer q Nut q Guide q Guide q Guide q Guide q Bolt q Washer q Nut Puller Pump Push tool q Sleeve q Sleeve q Plate q Guide q Guide q Bolt q Washer q Nut Push tool Push tool Push tool Push tool

t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t t

1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1

Q Q Q Q Q Q Q Q Q Q Q

Q Q Q Q Q Q

Q Q Q Q

50-268

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Undercarriage and frame Removal and installation of center hinge pin

5. Center drive shaft Sling and remove center drive shaft (17).
4

[*4] Center drive shaft: 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 steering demand valve. q Hoses (14) between work equipment pump and work equipment valve. q Hose (15) between hydraulic oil cooler and steering demand valve. q Hoses (16) between hydraulic tank and work equipment valve.

6. PPC hose and harness Disconnect the following hoses and harnesses. q Hoses (18) and (19) between EPC valve and work equipment valve. q Hoses (20) and (21) between rotary valve and steering demand valve. q Auto greasing hose (22) q Brake hose(23) q Wiring harness (24) a Tag each hose for identification.

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Undercarriage and frame Removal and installation of center hinge pin

7. Supporting frame 1) Using a crane, etc., place stand [1] under the front frame.

8. Lower hinge pin 1) Remove mounting bolts (27) and (28), then 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).

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Undercarriage and frame Removal and installation of center hinge pin

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). a Shims (44) are between the retainer and frame. Note the number and thickness of the shims for installation purpose.

12. Front frame 1) Remove mounting bolt (47) and retainer (48). a Shims (49) are between the retainer and 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).

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50-271

Undercarriage and frame Removal and installation of center hinge pin

3) Remove dust seal (52) from retainer (48).

4) Remove bearing (53). 5) Remove bushings (54) and (55).

50-272 Installation q perform installation in the reverse order to removal. 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 periphery 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 with that in the rear frame. 2) Install eyebolts into two pin bolt holes (at the diagonal positions) and sling pin (1) to install. k Be sure to support the pin at the bottom. 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). a Install the bushings so that their mating faces (d) are in the horizontal direction. 4) Remove two eyebolts. 5) Install retainer (7) and partially tighten six 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). a Install the bushings so that their mating faces (d) are in the horizontal direction. 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 specified torque. 3 Mounting bolt: 824 to 1030 Nm {84 to 105 kgm}

50-272

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Undercarriage and frame Removal and installation of center hinge pin

50-273 Procedure for installing center hinge pin 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 machine)

[*4]

Center drive shaft mounting bolt: 343 to 427 Nm {35 to 43.5 kgm}

2. Front frame 1) Using tool K1, press fit bearing assembly (53) to the top of frame (57). a For tool K1, see the "Sketches of special tools". a Check that the bearing outer race are press fitted to the bottom. 3 Bore of frame in which bearing is press fit: Molybdenum disulphide lubricant (LM-P) a The bearing consists of selective combination parts and its clearance is adjusted properly. Do not change the combination parts. a When assembling the bearings, apply grease sufficiently inside the bearings.

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Undercarriage and frame Removal and installation of center hinge pin

2) Install retainer (48) and partially tighten six mounting bolts (47). a Be careful not to tighten the bolts unevenly. 3 Mounting bolt: 137 Nm {14 kgm} 10% 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}

6) Using tool K3, install dust seal (51) to the frame with seal lip (56) facing outward, and install plate (50) as a stopper. a For tool K3, see the "Sketches of special tools". q Tool part No.: SMT-890-2430

7) Using tool K2, press fit bushings (54) and (55) to the hinge portion at the bottom of the frame. a For tool K2, see the "Sketches of special tools".

50-274

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Undercarriage and frame Removal and installation of center hinge pin

3. Rear frame 1) Using tool K1, press fit bearing assembly (46) to the bottom of frame (58). a For tool K1, see the "Sketches of special tools". a Check that the bearing outer race are press fitted to the bottom. a The bearing consists of selective combination 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. a For tool K3, see the "Sketches of special tools". q Tool part No.: SMT-890-2410

2) Install retainer (43) and partially tighten ten mounting bolts (42). a Be careful not to tighten the bolts unevenly. 3 Mounting bolt: 441 Nm {45 kgm} 10% 3) Loosen mounting bolts (42) once, and tighten them again with the torque specified in Step 2) taking care not to tighten them unevenly. 4) Measure the clearance between retainer (43) and rear frame (58) at four equally divided points on the circumference, and calculate average clearance "e". Select shims (44) so that average clearance "e" 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 (44) selected in Step 4) 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}

7) Install bushing (39) to the hinge portion at the bottom of the frame.

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50-275

Undercarriage and frame Removal and installation of center hinge pin

8) Install bushing (38) to the hinge portion at the top of the frame.

5) Remove retainer mounting bolts (34) and (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): Adhesive (LOCTITE #262) 3 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), tighten two mounting bolts (34), and install two eyebolts in the remaining bolt holes. 2) Insert upper hinge pin (37) through front frame (57) and rear frame (58), and remove the eyebolts. 3) Tighten four mounting bolts (34) and six mounting bolts (35) of retainer (36), and then hit the head of upper hinge pin (37) three to five times with a copper hammer. 3 Mounting bolts (34) and (35): 824 to 1,030 Nm {84 to 105 kgm} 4) To fit in contact parts with each other, repeat Step 3) three times, and then tighten retainer mounting bolts (34) and (35) again to the torque specified in Step 3). 6. Lower hinge pin 1) Insert lower hinge pin (32) into the lower hinge, insert bushing (33), and partially tighten retainer (29). 2) Place the jack under the bottom of the lower hinge of rear frame (58) to keep front frame (57) and bushing (39) closely contact and no space between them. 3) Tighten ten mounting bolts (27) and four mounting bolts (28) of retainer (29), and then hit the head of lower hinge pin (32) three to five times with a copper hammer. 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} 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

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Undercarriage and frame Removal and installation of center hinge pin

5) Taking care not to move rear frame (58), remove all of the ten bolts (27), and measure clearance "f" between retainer (29) and front frame (57) at three points (120 deg. interval) on the circumference with feeler gauge. Then calculate average clearance "f". Select shims (30) so that average clearance "f" 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. 6) Install shims (30) selected in Step 5) 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. 2 Mounting bolts (27) and (28): Adhesive (LOCTITE #262) 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}

Refilling Supply hydraulic oil through the oil filter port to the specified level. 5 Hydraulic oil: approx. 1,125 l

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

Undercarriage and frame Removal and installation of center hinge pin

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 pin LH: Lower hinge pin LI: Injector for lower hinge pin 1. Refill of grease into grease pump case 1) Check with level indicator (1) that grease is inside grease pump case (2). a Supply the grease if the level is low. 5 Grease pump case: Lithium grease (G2-LI)

FF: Front frame RF: Rear frame

2) Check that grease does not leak between grease pump case (2) and follower plate (2). a Be sure to use follower plate (3). (If follower plate (3) is not used, the pump cannot suction grease even if a sufficient volume of grease is in the grease pump case.)

50-278

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Undercarriage and frame Removal and installation of center hinge pin

3) Turn starting switch (4) to ON position, and check that auto-greasing indicator lamp (L) lights up on the monitor panel. q Lamp on: Normal q Lamp off: Circuit is open, main piping is broken, or grease inside the grease pump is empty.

2. Operation of auto-greasing system 1) The auto-greasing system starts automatically when starting switch (4) of the machine is turned to ON position. 2) Pressing auto-greasing switch (5) starts the grease pump irrespective of the timer. 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 pressure 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.

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50-279

Undercarriage and frame Removal and installation of center hinge pin

3. Adjusting delivery from injector q Injectors (UI) and (LI) is activated by pressure from the pump, and deliver the set volume of grease to bearings. q Perform greasing at the maximum delivery rate after installation of the center pin. 1) Loosen lock nut (6). 2) Tighten adjustment screw (7) clockwise until it contacts stopper. (Minimum delivery 0.13 cc/stroke) 3) Rotate adjustment screw (7) ten turns counterclockwise to loosen the screw. (Maximum delivery: 1.3 cc/stroke) 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

5] Tighten plugs (8) so that no leakage may occur. a The pressure gauge does not indicate whether air is bled. a If only small volume of air is left in the circuit, the system operates normally because the delivery of grease pump is high. a Whether or not the system runs normally is determined by whether the grease pump stops in balance within a predefined time (operating time (60 sec.)).

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. 3] Discharge grease mixed with air (milky) from the air bleeding ports of the injectors. 4] When normal grease comes out, press the auto-greasing switch to stop the grease pump.

2) Bleeding air from pressure switch portion 1] A worker removes pressure switch (10) 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 must presses the auto-greasing switch to start the grease pump. 3] Discharge grease mixed with air (milky) from block (9).

50-280

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Undercarriage and frame Removal and installation of center hinge pin

4] When normal grease comes out, press the auto-greasing switch to stop the grease pump. 5] Install pressure switch (10) on block (9). a Make sure that no grease is leaked.

5. Checking the supply line pressure Check that grease pump pressure gauge (11) and grease supply line pressure gauge (10) indicate 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 auto-greasing switch to start the grease 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 until specified pressure is reached. WA1200-6 50-281

Undercarriage and frame Removal and installation of center hinge pin

6. Checking operation of injector 1) Turn starting switch (4) to ON position, and press auto-greasing switch (5).

2) Check that indicator pin (12) runs normally.

7. Greasing to the center hinge pin 1) Turn starting switch (4) to ON position, and press auto-greasing switch (5).

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Undercarriage and frame Removal and installation of center hinge pin

2) Keep pumping new grease until it spills out of the center hinge pin.

2) Set fitting (15) of the grease gun to grease 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

Hydraulic system

Removal and installation of hydraulic tank, filter case assembly

Removal 50-284 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil:

50-284

50-284

6. Disconnect hydraulic oil temperature sensor connector HS1 (6). 7. Remove couplings (7) and (8). 8. Sling suction tube (9), disconnect bracket (10) and remove suction tube (9). 9. Disconnect tubes (11), (12), and (13).

approx. 1,125 l

2. Lift and remove handrails (1) and (2). 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).

5. Remove cover (5).

11. Disconnect hoses (17), (18), and (19). 12. Disconnect tube (20) at the intermediate connection.

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Hydraulic system Removal and installation of hydraulic tank, filter case assembly

13. Sling the hydraulic tank and filter case assembly (21), remove mounting bolts (22), and then remove the hydraulic tank and filter case assembly. [*1] 4 Hydraulic tank and filter case assembly: 1,370 kg

Installation
q

50-285

perform installation in the reverse order to the removal.

[*1]

Hydraulic tank mounting bolt: 824 to 1,030 Nm {84 to 105 kgm}

Flushing hydraulic circuit If the pump is replaced for an internal damage, flush the hydraulic circuit by referring to "Flushing procedure for work equipment and steering hydraulic circuit". Refilling with oil (hydraulic tank) Refill the hydraulic tank with 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. 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

Removal 50-286 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil: 4. Remove U-bolt (8). 5. Disconnect suction tube (9).

50-286

approx. 1,125 l

2. Open the upper step cover and remove step (1).

6. Disconnect hoses (10) and (11). 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

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Hydraulic system Removal and installation of No. 1 work equipment pump assembly

Installation
q

50-287

perform installation in the reverse order to the removal.

[*1]

Pump assembly mounting bolt: 455 to 565 Nm {46.5 to 58 kgm}

Flushing hydraulic circuit If the pump is replaced for an internal damage, flush the hydraulic circuit by referring to "Flushing procedure for work equipment and steering hydraulic circuit". Refilling with oil (hydraulic tank) Refill the hydraulic tank with oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Air bleeding Bleed air from the hydraulic circuit. For details, see "Bleeding air from work equipment hydraulic circuit and steering hydraulic circuit".

WA1200-6

50-287

Hydraulic system Removal and installation of No. 2 work equipment pump assembly

Removal and installation of No. 2 work equipment pump assembly

Removal 50-28 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil: 2. Open the upper step cover. 3. Disconnect hoses (1), (2), (3), (4), and (5). 4. Remove pump outlet hoses (6), (7), and (8). 5. Disconnect suction tubes (9) and (10). 6. Sling work equipment pump assembly (11), remove mounting bolts, and then remove the work equipment pump assembly. [*1] 4 Work equipment pump assembly: 180 kg
q

50-28
50-28

Installation
q

perform installation in the reverse order to the removal. Pump assembly mounting bolt: 455 to 565 Nm {46.5 to 58 kgm}

[*1] approx. 1,125 l

q

Flushing hydraulic circuit If the pump is replaced for an internal damage, flush the hydraulic circuit by referring to "Flushing procedure for work equipment and steering hydraulic circuit". Refilling with oil (hydraulic tank) Refill the hydraulic tank with oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Air bleeding Bleed air from the hydraulic circuit. For details, see "Bleeding air from work equipment hydraulic circuit and steering hydraulic circuit".

50-288

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Hydraulic system Removal and installation of switch pump assembly

Removal and installation of switch pump assembly

Removal 50-289 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Drain the hydraulic oil. 6 Hydraulic oil: 2. Open the upper step cover. 3. Disconnect hoses (1) and (2). 4. Disconnect hoses (3) and (4). 5. Remove hose and disconnect suction tube (6). 6. Disconnect hose (7). 7. Disconnect hoses (8) and (9). 8. Sling the switch pump assembly, remove mounting bolts, and then remove the switch pump assembly. [*1] 4 Switch pump assembly: 250 kg
q q

50-289
50-289

Installation
q

perform installation in the reverse order to the removal. Pump assembly mounting bolt: 455 to 565 Nm {46.5 to 58 kgm}

[*1] approx. 1,125 l

q

Flushing procedure for hydraulic circuit If the pump is replaced for an internal damage, flush the hydraulic circuit by referring to "Flushing procedure for work equipment and steering hydraulic circuit". Refilling with oil (hydraulic tank) Refill the hydraulic tank with oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again. Air bleeding Bleed air from the piston pump and work equipment hydraulic circuit. For details, see "Bleeding air from piston pump" and "Bleeding air from 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

Preparation work 1. Before starting maintenance work, measure the raising speed of the work equipment.

50-290

a Work equipment control valve check sheet

Standard value 1,900 rpm Specifications Engine (rpm) Work equipment speed (High idle) (sec) Low idle High idle Work equipment circuit relieved At torque converter stall Full stall Lift arm Raise Lift arm Lower Bucket Tilt (on ground) Bucket dump (no load) New machine 650 25 1,900 50 1,750 to 1,950 1,750 to 1,950 1,600 to 2,000 13.5 0.5 5.3 0.5 4.1 0.3 2.7 0.3 Machine Serial No.: Replacement of control valve Before After

50-290

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Hydraulic system Removal and installation of work equipment control valve assembly

2. Clean around the control valve. Around cover

Removal

50-291

1. Drain the hydraulic oil. 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.
4

[*1] Cover: 21 kg

Around the control valve and piping

q k k

Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". Perform the following work before stopping the engine. Raise the lift arm and place it on lift arm support [1]. Set ladder [2].

WA1200-6

50-291

Hydraulic system Removal and installation of work equipment control valve assembly

3. Remove the front work equipment control valve assembly according to the following procedure. 1) Remove tubes (2), (3), (4), (5), (6), and (7). a Do not reuse the removed O-rings but replace them with new ones. 2) Remove hoses (8), (9), (10), and (11). a Do not reuse elbows, unions, and O-rings but replace them with new ones, to prevent incorrect assembly. 3) Remove three mounting bolts for front work equipment control valve assembly (12).

a When removing hoses and tubes, be careful not to let dirt or dust enter the tubes. a Place the bolts and washers in a plastic bag and keep it with the tube. a Cover the ends of the removed tubes with pieces of plastic sheet, as the tubes are reused. a Do not plug the tube openings with wood or cork pieces. (Their particles may enter and cause serious problems.)

a Before removing hoses and tubes, put numbers (N) on the control valve, and hoses and tubes to indicate their installed positions.

4) Install lifting tool. a Eyebolt size: M12 x 1.75 5) Lift and remove front work equipment control valve assembly (12). 4 Front work equipment control valve assembly: 95 kg

50-292

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Hydraulic system Removal and installation of work equipment control valve assembly

4. Remove the center work equipment control valve assembly according to the following procedure. 1) Remove tubes (13), (14), (15), (16), (17), and (18). a Do not reuse the removed O-rings but replace them with new ones. 2) Remove hoses (19), (20), (21), and (22). a Do not reuse elbows, unions, and O-rings but replace them with new ones, to prevent incorrect assembly. 3) Remove three mounting bolts for center work equipment control valve assembly (23).

a When removing hoses and tubes, be careful not to let dirt or dust enter the tubes. a Place the bolts and washers in a plastic bag and keep it with the tube. a Cover the ends of the removed tubes with pieces of plastic sheet, as the tubes are reused. a Do not plug the tube openings with wood or cork pieces. (Their particles may enter and cause serious problems.)

a Before removing hoses and tubes, put numbers (N) on the control valve, and hoses and tubes to indicate the installed positions.

4) Install lifting tool. a Eyebolt size: M12 x 1.75 5) Lift and remove center work equipment control valve assembly (23). 4 Center work equipment control valve assembly: 95 kg

WA1200-6

50-293

Hydraulic system Removal and installation of work equipment control valve assembly

5. Remove the rear work equipment control valve assembly according to the following procedure. 1) Remove tubes (24), (25), (26), (27), (28), and (29). a Do not reuse the removed O-rings but replace them with new ones. 2) Remove hoses (30), (31), and (32). a Do not reuse elbows, unions, and O-rings but replace them with new ones, to prevent incorrect assembly. 3) Remove three mounting bolts for rear work equipment control valve assembly (33).

a When removing hoses and tubes, be careful not to let dirt or dust enter the tubes. a Place the bolts and washers in a vinyl bag and keep it with the tube. a Cover the ends of the removed tubes with pieces of plastic sheet, as the tubes are reused. a Do not plug the tube openings with wood or cork pieces. (Their particles may enter and cause serious problems.)

a Before removing hoses and tubes, put numbers (N) on the control valve, and hoses and tubes to indicate the installed positions.

4) Install lifting tool. a Eyebolt size: M12 x 1.75 5) Lift and remove rear work equipment control valve assembly (33). 4 Rear work equipment control valve assembly: 95 kg

50-294

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Hydraulic system Removal and installation of work equipment control valve assembly

6. Remove two bracket mounting bolts and remove bracket (34). 4 Work equipment control valve mounting bracket: 45 kg

WA1200-6

50-295

Hydraulic system Removal and installation of work equipment control valve assembly

Installation

50-296

a Do not reuse control valve, PPC piping (hose, elbow, nipple), cushion, plate insulator, bolts, and washers, but replace them with new ones.

a Do not reuse deteriorated rubbers or elbows, unions, hoses smeared with oil as shown below.

1. Plug the PPC piping.

50-296

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Hydraulic system Removal and installation of work equipment control valve assembly

2. Clean the inside of front frame with detergent. 3. Install bracket (34) according to the following procedure. 1) Place two cushions at the mounting part on front frame (36). 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 mounting bolts (41). 3 Mounting bolt: 235 to 285 Nm {23.5 to 28.5 kgm}

4. Install rear work equipment control valve assembly, center work equipment control valve assembly, and front work equipment control valve assembly to the bracket in this order. 3 Control valve mounting bolt: 235 to 285 Nm {23.5 to 28.5 kgm}

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50-297

Hydraulic system Removal and installation of work equipment control valve assembly

5. Install hoses and tubes according to the following procedure. 1) Installation of hoses and tubes (1)

2) Installation of hoses and tubes (2)

50-298

WA1200-6

Hydraulic system Removal and installation of work equipment control valve assembly

3) Installation of hoses and tubes (3)

4) Installation of hoses and tubes (4)

WA1200-6

50-299

Hydraulic system Removal and installation of work equipment control valve assembly

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 Removal and installation of work equipment control valve assembly

WA1200-6

50-301

Hydraulic system Removal and installation of work equipment control valve assembly

6) Installation of pilot hose (installation of clamp)

50-302

WA1200-6

Hydraulic system Removal and installation of work equipment control valve assembly

Perform the subsequent installation in the reverse 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

Flushing hydraulic circuit When repairing the valve that is internally damaged, flush the hydraulic circuits. For details, see "Flushing procedure for work equipment and steering hydraulic circuit". Refilling with oil (hydraulic tank) Refill the hydraulic tank with 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. Air bleeding Bleed air from the hydraulic circuit. For details, see "Bleeding air from work equipment hydraulic circuit and steering hydraulic circuit".

WA1200-6

50-303

Work equipment Removal and installation of bucket cylinder assembly

Work equipment
Special tools

Removal and installation of bucket cylinder assembly

New/redesign

50-304
50-304

50-304

Necessity

Symbol

Part No.

Part name

Sketch Q Q Q Q Q Q Q Q Q Q Q Q

Q'ty

Detail of work, remarks

3 T 4 10 13 14 15

SMT-890-5480 SMT-890-5491 SMT-890-5300 SMT-890-5310 SMT-890-5320 SMT-890-5330 SMT-890-5340 SMT-890-5350 SMT-890-5370 SMT-890-5050 SMT-890-5070 42C-98-11320 01017-51245 01010-81230 42C-98-11350

Forcing bolt Flanged nut Push puller assembly q Plate q Guide bar q Flange nut q Push bolt q Leveling pad q Adapter (for 24 mm) Plate Bolt Plate Bolt Bolt Plate

q q q q q q q q q q q q q q q

2 2 1 1 2 1 1 1 2 1 4 1 2 2 1

Removal of work equipment pin (for f180 mm)

Installation of work equipment pin

Removal of collar (for f180 and f240 mm)

Collar stopper plate (for f180 mm) Collar tap bolt Collar stopper plate tap bolt Q Fixing plate for press fit of bushing

How to use special tools 1. How to use work equipment pin removal tool (T1) a Use removal tool T1 to remove the work 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 2) Through clearance (a) made in Step 1), install the flanged nut of tool T1 (T1-2) into the flange hole of pin (10).

50-304

WA1200-6

Work equipment Removal and installation of bucket cylinder assembly

3) Screw in forcing bolt (T1-1) of tool T1 into flanged nut (T1-2) installed in Step 2) to remove pin (10).

1) Install the plate of T4. Since the plate can be used for both pins of f180 and 240 mm in 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 removal tool T4. a Select the bolt hole in the plate of the tool according to the pin diameter. Reference: Tool T4 can be used for both pin diameters f180 mm and f240 mm. a As the diameter of pins at the piston rod and 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.)

2) Install four bolts (M12, L = 50 mm) in bolt holes (a) to secure the plate (T4-1) of tool T4 to collar A (11) or collar B (12). a Use the collar forcing tap hole and use the washer, too. 3) Tighten forcing bolt (T4-2) of tool T4 to remove collar A (11) or collar B (12).

WA1200-6

50-305

Work equipment Removal and installation of bucket cylinder assembly

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 Tool T3, has adapters (SMT-890-5370) for 24-mm bolt hole and (SMT-890-5360) for 30-mm bolt hole. Use adapter SMT-890-5370 for 24-mm bolt hole.

2) Insert tool guide bar (T3-2) into the flange bolt hole of pin (10), then install tool adapter (T3-6) to the pin flange mounting bolt hole. 3) Screw in tool bolt (T3-4) to 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 installed to the collar from coming off, never hit the pin with a hammer to insert it.

4. How to install collar stopper plates (T10, T13, and T14) a The collar stopper plates T10, T11 and T12, and bolts T13 and T14 are provided for each machine as standard attached tools. a For part numbers of tools T11 and T12, see "Special tool list". a Use tool T10, T11 or T12 depending on the diameter of the mounting pin. Tool T10: For pin of f180 mm Tool T11: For pin of f240 mm Tool T12: For pin of f280 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 install 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 stopper 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 plates T10, T11 and T12. 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 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 cylinder (240-mm pin) q Joint between bucket cylinder bottom and front frame (180-mm pin)

50-306

WA1200-6

Work equipment Removal and installation of bucket cylinder assembly

11. Collar A 11A. Collar boss on pin flange side 12. Collar B 12A. Collar boss on pin tip side Reference: The portion to which the collar is installed is referred to as "collar boss".

B type: When female threads for fixing the collar stopper plate are cut directly in collar boss (12A). q Joint between bell crank and piston rod bucket cylinder (180-mm pin) 11. Collar A 11A. Collar boss on pin flange side 12. Collar B 12A. Collar boss on pin tip side

C type: When a dirt intrusion prevention ring screw is used for securing the collar stopper plate. 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. 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) 24. Bolt (ring horizontalization bolt) (*1) 26. Ring (dirt intrusion prevention ring) (*2) 27. Snap ring (*2) 28. Bolt (ring horizontalization bolt) (*2) (*1): Joint between lift arm and bucket (*2): Joint between bucket link and bucket, and joint between bucket link and bell crank

WA1200-6

50-307

Work equipment Removal and installation of bucket cylinder assembly

Features of work equipment connecting part 50-308 1. Lubrication of work equipment joints Lubricated type work equipment pins and bushings are 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 performance. 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.

q q

Clearance without tension: 5.1 mm Appropriate clearance after shim adjustment: 0.5 to 0.7 mm

50-308

WA1200-6

Work equipment Removal and installation of bucket cylinder assembly

Preparation of work foothold (reference) 50-309 Before removing the bucket cylinder, take the following steps to install work foothold [1]. 1. Assembling work foothold [1] 1) Install deck plates [1-9] to [1-13] on deck [1-2] with bolts. 2) Sling deck [1-2], install stand [1-8] to it with bolts.

2. Installing work foothold [1] 1) Place work foothold [1] to its installed position on the bucket and lift arms. a Position the end of stand [1-8] above the level part of the bucket top. a Position the other end above the lift arms. 2) Secure right and left legs [R] to bucket [B] by 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 Removal and installation of bucket cylinder assembly

General view after installation

50-310 Removal k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 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 cover 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 Removal and installation of bucket cylinder assembly

4

Mounting pin:

70 kg a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool (T1)" in the "How to use special tools".

a Dust seal (15) is installed to the machines with serial number 50077 and up.

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. k After retracting the piston rod, stop the engine, loosen the hydraulic tank oil filler cap to release pressure inside the tank. Then operate the work equipment 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 procedure using special tool T4, see "2. How to use collar removal tool (T4)" in the "How to use special tools". 2. Wiring harness connector q Disconnect harness connector F13 (42). 3. Hose q Disconnect hoses (43) and (44).

4. Removal of pin connecting front frame and bucket cylinder 1) Remove mounting bolts (17) and four washers (18) of cover (19) installed to mounting pin (10) connecting front frame (7) and cylinder bottom (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 cover 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

W o rke q u ip m e n t Removal and installation of bucket cylinder assembly

2) Remove pin flange fixing bolts (8) and four spacers (9) of mounting pin (10), pull out mounting pin (10) using special tool T1, and disconnect cylinder bottom (6) of the bucket cylinder from front frame (7). k Check that the bucket cylinder assembly is slung securely, and then pull out the mounting pin. 4 Mounting pin: 70 kg a For the mounting pin removal procedure, see 1. How to use work equipment pin removal tool" in the "How to use special tools".

4) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

5) Taking the same procedures in Steps 1) to 4), remove the other mounting pin connecting the front frame and cylinder bottom of the bucket cylinder. 5. Bucket cylinder assembly q Sling bucket cylinder assembly (6) and remove it. 4 Bucket cylinder assembly (one unit): 1,400 kg 3) Remove collar A (11) and collar B (12) from front frame (7). a Length of collar q Collar A (11) and collar B (12): 109.3 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

50-312

WA1200-6

Work equipment Removal and installation of bucket cylinder assembly

6. 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 bushing (13) at four places to remove it. 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".

Outline of shim selection for installing mounting 50-313 pin (Outline of shim adjustment procedure) q Outline of shim adjustment a 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).

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 Removal and installation of bucket cylinder assembly

50-314 Installation 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 hydraulic cylinder, piping, and hoses, and supply oil through the hydraulic tank oil filler to the specified level. Flushing of hydraulic circuits When repairing the cylinder that is internally damaged, perform flushing of hydraulic circuits. For details, see "Flushing procedure for work equipment and steering circuit". Air bleeding Bleed air from the hydraulic circuit. For details, see "Bleeding air from work equipment circuit and steering circuit". 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

Special tools
New/redesign Necessity Symbol L1 2 Sketch

50-315
50-315

Part No.

Part name

Q'ty

Detail of work, remarks

3 T

4 11 13 14 15

793T-870-1410 SMT-890-5460 SMT-890-5471 SMT-890-5300 SMT-890-5310 SMT-890-5320 SMT-890-5330 SMT-890-5340 SMT-890-5350 SMT-890-5360 SMT-890-5050 SMT-890-5070 42C-98-11330 01017-51245 01010-81230 42C-98-11350

stand Forcing bolt Flanged nut Push puller assembly q Plate q Guide bar q Flange nut q Push bolt q Leveling pad q Adapter (for 30 mm) Plate Bolt Plate Bolt Bolt Plate

q q q q q q q q q q q q q q q q

1 2 2 1 1 2 1 1 1 2 1 4 1 2 2 1

Q Q Q Q Q Q Q Q Q Q Q Q Q

Support for front frame Removal of work equipment pin (for f240 and 280 mm)

Installation of work equipment pin

Removal of collar (for f180 and 240 mm)

Collar stopper plate (for f240 mm) Collar tap bolt Collar stopper plate tap bolt Q Fixing plate for press fit of bushing

How to use special tools 1. How to use work equipment pin removal tool (T2) a Use removal tool T2 to remove the work 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.

50-315 2) Through clearance (a) made in Step 1), install the flanged nut of tool T2 (T2-2) into the flange hole of pin (10).

WA1200-6

50-315

Work equipment Removal and installation of lift cylinder assembly

3) Screw in forcing bolt (T2-2) of tool T2 into flanged nut (T2-1) installed in Step 2) to remove pin (10).

1) 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.

2. How to use collar removal tool (T4) a If the collar is hard to remove, use collar removal tool T4. a Select bolt hole in the plate of the tool according to the pin diameter. Reference: Tool T4 can be used for both pin diameters f180 mm and f240 mm. 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.)

2) Install four bolts (M12, L = 50 mm) in bolt holes (a) to secure the plate (T4-1) of tool T4 to collar A (11) or collar B (12). a Use the collar forcing tap hole and use the washer, too. 3) Tighten forcing bolt (T4-2) of tool T4 to remove collar A (11) or collar B (12).

50-316

WA1200-6

Work equipment Removal and installation of lift cylinder assembly

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 Tool T3 has adapters (SMT-890-5370) for 24-mm bolt hole and (SMT-890-5360) for 30-mm bolt hole. Use adapter SMT-890-5360 for 30-mm bolt hole.

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 installed to the collar from coming off, never hit the pin with a hammer to insert it.

4. How to install collar stopper plates (T11, T13, and T14) a The collar stopper plates T10, T11 and T12, and bolts T13 and T14 are provided for each machine as standard attached tools. a For part numbers of tools T10 and T12, see "Special tools list". a Use tool T10, T11 or T12 depending on the diameter of the mounting pin. Tool T10: For pin of f180 mm Tool T11: For pin of f240 mm Tool T12: For pin of f280 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 install 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 stopper 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 plates T10, T11 and T12.

WA1200-6

50-317

Work equipment Removal and installation of lift cylinder assembly

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 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) 11. Collar A 11A. Collar boss on pin flange side 12. Collar B 12A. Collar boss on pin tip side Reference: The portion to which the collar is installed is referred to as "collar boss".

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. 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) 24. Bolt (ring horizontalization bolt) (*1) 26. Ring (dirt intrusion prevention ring) (*2) 27. Snap ring (*2) 28. Bolt (ring horizontalization bolt) (*2) (*1): Joint between lift arm and bucket (*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 bucket cylinder (180-mm pin) 11. Collar A 11A. Collar boss on pin flange side 12. Collar B 12A. Collar boss on pin tip side

50-318

WA1200-6

Work equipment Removal and installation of lift cylinder assembly

Features of work equipment connecting part 50-319 1. Lubrication of work equipment joints Lubricated type work equipment pins and bushings are 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 performance.

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. q Clearance without tension: 5.1 mm q Appropriate clearance after shim adjustment: 0.5 to 0.7 mm

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Work equipment Removal and installation of lift cylinder assembly

50-320 Removal Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 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.
k

2) Install foothold [3] on the front of the front support.

[If tires are not removed] 1. Sling front fender (42) and remove it. 4 Front fender:

50-320 140 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

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Work equipment Removal and installation of lift cylinder assembly

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 a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special 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. 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 cover 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).

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Work equipment Removal and installation of lift cylinder assembly

5) Start the engine and retract the piston rod of lift arm cylinder. k After retracting the piston rod, stop the engine, loosen the hydraulic tank oil filler cap to release pressure inside the tank. Then operate the work equipment control lever two or three times to release the remaining pressure in the piping. 6) Remove collar A (11) and collar B (12) from lift arm (1). q Length of collar A (11) and collar B (12): 101.8 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

8) Disconnect hoses (43) and (44).

9) Taking the same procedures in Steps 1) to 8), remove the other mounting pin connecting the lift arm and piston rod of the lift arm cylinder. 4. Removal of pin connecting front frame and lift arm cylinder bottom 1) Remove mounting bolts (17) and washers (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. 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 cover is removed.

7) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

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Work equipment Removal and installation of lift cylinder assembly

2) 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 a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

4) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

5) Taking the same procedures in Steps 1) to 4), remove the other mounting pin connecting the lift arm and lift arm cylinder bottom. 3) Remove collar A (11) and collar B (12) from front frame (7). a Length of collar q Collar A (11): 183.3 mm (Outside of the machine) q Collar B (12): 121.8 mm (Inside of the machine) 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use 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. Lift arm cylinder assembly q Sling lift arm cylinder assembly (5) and remove it. 4 Lift arm cylinder assembly: 2,950 kg

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Work equipment Removal and installation of lift cylinder assembly

6. 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 bushing (13) at four places to remove it. 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".

[If tires are removed] 1. Preparation of work foothold 1) Lift up the front frame and set tool L1.

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2) Raise the lift arm and place it on lift arm stand [1].

3) Install foothold [2] on the front of the front support.

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Work equipment Removal and installation of lift cylinder assembly

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.

2. Removal of pin connecting lift arm and piston rod of lift arm cylinder 1) Sling arm lift arm cylinder assembly (5). 4 Lift arm cylinder assembly: 2,950 kg

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 a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the How to use special tools "How to use special 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. 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 cover is removed.

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Work equipment Removal and installation of lift cylinder assembly

4) Start the engine and retract the piston rod of lift arm cylinder. k After retracting the piston rod, stop the engine, loosen the hydraulic tank oil filler cap to release pressure inside the tank. Then operate the work equipment control lever two or three times to release the remaining pressure in the piping. 5) Remove collar A (11) and collar B (12) from lift arm (1). q Length of collar A (11) and collar B (12): 101.8 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

7) Disconnect hoses (43) and (44).

3. Removal of pin connecting front frame and lift arm cylinder bottom 1) Remove mounting bolts (17) and washers (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. 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 cover is removed.

6) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12). a Dust seal (15) is installed to the machine with serial number 50077 and up.

2) 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 a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

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3) Remove collar A (11) and collar B (12) from front frame (7). a Length of collar q Collar A (11): 183.3 mm (Outside of the machine) q Collar B (12): 121.8 mm (Inside of the machine) 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use 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.

4. Lift arm cylinder assembly q Sling lift arm cylinder assembly (5) and remove it. 4 Lift arm cylinder assembly: 2,950 kg

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 bushing (13) at four places to remove it. 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". 4) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

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Work equipment Removal and installation of lift cylinder assembly

Outline of shim selection for installing mounting 50-328 pin (Outline of shim adjustment procedure) q Outline of shim adjustment a 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).

50-328 Installation a Install the lift arm cylinder assembly. For details, see "Installation" of "Removal and installation of work equipment assembly".
q

Refilling a Start the engine, circulate hydraulic oil in hydraulic cylinder, piping, and hoses, and supply oil through the hydraulic tank oil filler to the specified level. Flushing of hydraulic circuits When repairing the cylinder that is internally damaged, perform flushing of hydraulic circuits. For details, see "Flushing procedure for work equipment and steering circuit". Air bleeding Bleed air from the hydraulic circuit. For details, see "Bleeding air from work equipment circuit and steering circuit". Running in a Perform running-in operation. For details, see "Procedure for running in lift arm pin".

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".

50-328

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Work equipment Disassembly and assembly of work equipment cylinder

Disassembly and assembly of work equipment cylinder

Special tools
Symbol

50-329

50-329
Necessity Q'ty New/redesign Sketch

2) Remove mounting bolts (3) of head cover (2).

Part No.

Part name

2 790-502-1003 Cylinder repair stand 3 790-720-1000 Expander 796-720-1720 Ring 07281-02429 Clamp U 4 796-720-1730 Ring 07281-03209 Clamp 5 790-102-3902 Wrench

q q q q q q q

1 1 1 1 1 1 1

Disassembly 1. Cylinder assembly 1) Set cylinder assembly (1) to tool U2. 4 Steering cylinder:
4 4

50-329

600 kg Bucket cylinder: 1,400 kg Lift arm cylinder: 3,000 kg

3) Pull out piston rod (4) from the cylinder. a As remaining oil inside the cylinder flows out when pulling out the rod, prepare an oil container. a If the piston rod is hard to be pulled out from the cylinder, slightly turn the piston rod and pull the cylinder.

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Work equipment Disassembly and assembly of work equipment cylinder

2. Piston rod q Steering cylinder 1) Remove lock screw (31) of piston assembly (30). q Screw size: M12 x pitch 1.75

Bucket cylinder and lift arm cylinder 1) Remove mounting bolts (5) and remove spacer (6). 2) Pull out piston (7) and cylinder head (2) from 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 tap [1], then remove the screw.

3. Piston 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).

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Work equipment Disassembly and assembly of work equipment cylinder

4. Head cover 1) Remove O-ring (19) and backup rings (20) from head cover (2) . 2) Remove bolt (21) and spacer (22). 3) Remove seals (23) and (24), collar (25), and seals (26) and (27) from spacer (22). 4) Remove rod packing (28) and buffer ring (29). 5) Remove snap ring (35) and bushing (36) from head cover (2).

50-3 1 Assembly a Clean each part, and when installing the U-packing, dust seal, and O-ring, take care not to damage them. 1. Head cover 1) Press fit bushing (36) to head cover (2) and install snap ring (35). 2) Install buffer ring (29) and rod packing (28). 3) install seals (27) and (26), collar (25), and 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 position. Warm it in warm water approximately 50 to 60 C before fitting it.

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Work equipment Disassembly and assembly of work equipment cylinder

2. Piston 1) Set piston ring (11) to tool U3 and expand it. a Set the piston ring to the tool, and then rotate the handle eight to ten times to expand the ring.

3. Piston rod q Steering cylinder 1) Install head cover (2) to cylinder rod (32). 2) Install two backup rings (8) and O-ring (9) to piston (30). a Do not try to force the backup ring into position. 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 following procedure. 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 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 four points on its periphery. a After tightening the screw, check that unfastening torque is 41.2 to 88.2 Nm {4.2 to 9 kgm}.

4) Install wear rings (10) to piston (7).

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Work equipment Disassembly and assembly of work equipment cylinder

4] Install screw (31). a Install the screw after degreasing and drying the threads completely. a After tightening the screw, punch it at four points on its periphery. 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 engaged, and make a horizontal hole. q Dimensions of a screw hole (mm): Tap drill diameter: 10.3 Tap hole depth: 43 Tap to be used: 12 x 1.75 Tap depth: 36 3] Remove steel chips and dust and clean the assembly completely.

Bucket cylinder and lift arm cylinder 1) Install head cover (2) onto cylinder rod (4). 2) Install two backup rings (8) and O-ring (9) to piston rod (4). a Do not try to force the backup ring into position. 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 accelerator to six positions after degreasing. 2 Hardening accelerator: Equivalent to LOCTITE Primer T a After applying hardening accelerator, apply 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).

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Work equipment Disassembly and assembly of work equipment cylinder

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}

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Work equipment Removal and installation of work equipment assembly

Removal and installation of work equipment assembly

Special tools
Symbol Standard equipment serial No.: 60001 and up STD STD STD STD STD STD STD STD STD STD STD New/redesign Necessity Sketch

50-3 5
50-3 5

Part No.

Part name

Q'ty

Detail of work, remarks

SMT-890-5480 SMT-890-5491 SMT-890-5460 2 SMT-890-5471 SMT-890-5300 SMT-890-5310 SMT-890-5320 SMT-890-5330 3 SMT-890-5340 SMT-890-5350 1 SMT-890-5360 SMT-890-5370 SMT-890-5050 T 4 SMT-890-5070 SMT-890-5060 5 SMT-890-5070 10 42C-98-11320 11 42C-98-11330 12 42C-98-11340 13 01017-51245 01011-81265 01011-81250 14 01011-81230 01010-81230 15 42C-98-11350

Forcing bolt Flanged nut Forcing bolt Flanged nut Push puller assembly q Plate q Guide bar q Flange nut q Push bolt q Leveling pad
q q

q q q q q q q q q q

2 2 2 2 1 1 2 1 1 1

Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q

Removal of work equipment pin (for f180 mm) Removal of work equipment pin ((for f240 and 280 pins)

Installation of work equipment pin

Adapter (30 mm) Adapter (24 mm)

q 2 q 2 q q q q q q q q 1 4 1 4 1 1 1 2

Plate Bolt Plate Bolt Plate Plate Plate Bolt Bolt Bolt Bolt Bolt Plate

(P-16) (Commercially available) For pin mounting bolt hole of 30 mm in diameter (*1) For pin mounting bolt hole of 24 mm in diameter (*2) Removal of collar (for f180 and 240 pins) Removal of collar (for f280 pin)

STD STD STD STD STD STD STD

q 2 q 2 q 2 q 2 q 1 Q

STD

Collar stopper plate for f180 pin Collar stopper plate for f240 pin Collar stopper plate for f280 pin Collar tap bolt for pins of any size Collar stopper plate mounting bolt (joint between lift arm and bucket) Collar stopper plate mounting bolt (joint between bucket link and bucket) Collar stopper plate mounting bolt (joint between lift arm and bell crank) Collar stopper plate mounting bolt (joint other than the above three joints) Fixing plate for press fit of 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

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Work equipment Removal and installation of work equipment assembly

50-3 6 Sketch of tool (for 42C-98-*****) a For SMT-890-*****, see the "Sketch of special tool". T10: 42C-98-11320 ((Collar stopper plate for f180 mm pin)

T15: 42C-98-11350 (Fixing plate for press fit of bushing)

T11: 42C-98-11330 ((Collar stopper plate for f240 mm pin)

T12: 42C-98-11340 ((Collar stopper plate for f280 mm pin)

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Work equipment Removal and installation of work equipment assembly

How to use special tools 1. How to use work equipment pin removal tool (T1 or T2) a Use removing tools T1 or T2 to remove the work equipment mounting pin. q Tool T1: For pin of f180 mm q Tool T2: For pins of f240 and 280 mm 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.

50-3 7 3) Screw in the forcing bolt of tool T1 or T2 (T1-1 or T2-1) into the flanged nut (T1-2 or T2-2) installed in Step 2) to remove pin (10).

2) Through clearance (a) made in Step 1), install the flanged nut of tool T1 or T2 (T1-2 or T2-2 ) to the flange hole of pin (10).

2. How to use collar removal tool (T4 or T5) a If the collar is hard to remove, use collar removal tool T4 or T5 to remove it. a Select plate T4 or T5 depending on the pin diameter. q Tool T4: For pin of f180 mm (A) : For pin of f240 mm (B) q Tool T5: For pin of f280 mm (C)

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.

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Work equipment Removal and installation of work equipment assembly

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

3) How to use (an example of use for f280 pin) (1) Install four bolts (M12, L = 50 mm) in bolt holes (a) to secure the plate (T5-1) of tool T5 to collar A (11) or collar B (12). a Use the collar forcing tap hole and use the washer, too. (2) Tighten forcing bolt (T5-2) of tool T5 to remove collar A (11) or collar B (12).

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 diameter of the pin flange mounting bolt hole. 24-mm bolt hole: SMT-890-5370 30-mm bolt hole: SMT-890-5360 3] Screw in bolt (T3-4) to 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 installed to the collar from coming off, never hit the pin with a hammer to insert it.

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4. How to install the attached tools (collar stopper plates (T10, T11, T12, T13 and T14) a The collar stopper pates T10, T11 and T12, and the bolts T13 and T14 are provided for each machine as standard attached tools. a Use tool T10, T11 or T12 depending on the diameter of the mounting pin. Tool T10: For pin of f180 mm Tool T11: For pin of f240 mm Tool T12: For pin of f280 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 install 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 stopper 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 plates T10, T11 and T12. 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 removing or installing the work equipment assembly 11. Collar A 11A. Collar boss on pin flange side 12. Collar B 12A. Collar boss on pin tip side

B type: When female threads for fixing the collar stopper plate are cut directly in collar boss (12A). q Joint between bell crank and piston rod bucket cylinder (180-mm pin) 11. Collar A 11A. Collar boss on pin flange side 12. Collar B 12A. Collar boss on pin tip side

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Work equipment Removal and installation of work equipment assembly

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. 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) 24. Bolt (ring horizontalization bolt) (*1) 26. Ring (dirt intrusion prevention ring) (*2) 27. Snap ring (*2) 28. Bolt (ring horizontalization bolt) (*2) (*1): Joint between lift arm and bucket (*2): Joint between bucket link and bucket, and joint between bucket link and bell crank

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Structure and name of work equipment connecting parts 1. Work equipment names and connecting parts

50-341

1. Lift arm 2. Bell crank 3. Bucket link 4. Bucket 5. Lift arm cylinder 6. Bucket cylinder 7. Front frame

A. Joint between bucket and lift arm B. Joint between bucket and bucket link C. Joint between bell crank and bucket link D. Joint between piston rod of bucket cylinder and bell crank E. Joint between bucket cylinder bottom and front 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 removing or installing the work equipment assembly

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Work equipment Removal and installation of work equipment assembly

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".

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Work equipment Removal and installation of work equipment assembly

3. Connecting part equipped with the dirt prevention ring (Joint between lift arm and bucket)

21. Ring (dirt intrusion prevention ring) 22. Snap ring 23. Bolt (top and bottom ring fixing bolt)

24. Bolt (ring horizontalization bolt) 25. Washer

(Joint between bucket link and bucket, and joint between bucket link and bell crank)

26. Ring (dirt intrusion prevention ring) 27. Snap ring

28. Bolt (ring horizontalization bolt) 29. Washer

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Work equipment Removal and installation of work equipment assembly

4. Features of work equipment connecting part 1. Lubrication of work equipment joints Lubricated type work equipment pins and bushings are 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 performance. 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.

q q

Clearance without tension: 5.1 mm Appropriate clearance after shim adjustment: 0.5 to 0.7 mm

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Removal k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 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 bucket and bucket link 1) Sling bucket link (3). 4 Bucket link: 650 kg

50-345 3) Remove mounting bolts (17) and washers (18) of cover (19) installed to mounting pin (10) connecting link (3) and bucket (4), and remove the cover. a When the cover is hard to remove, use the forcing tap to remove it. a Forcing tap: M12 x 1.75 (2 places) a Prepare an oil container since the oil in the mounting pin flows out when the cover is removed.

2) Remove fixing bolt (28) and washer (29) of ring (26) of the joint between bucket link (3) and bucket (4).

4) Remove four pin flange fixing bolts (8) and four spacers (9) of mounting pin (10), then pull out mounting pin (10) using special tool T1. 4 Mounting pin: 80 kg a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools". 5) Disconnect bucket link (3) from bucket (4), then remove ring (26) and snap ring (27). 4 Bucket link: 650 kg

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7) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

8) Taking the same procedures in Steps 1) to 7), remove the other mounting pin 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 6) Remove collar A (11) and collar B (12) from bucket (4). a Length of collar q Collar A (11) and collar B (12): 109.3 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

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2) Remove fixing bolts (28) and washers (29) of ring (26) of the joint between bucket link (3) and bell crank (2).

5) Disconnect bucket link (3) from bell crank (2), then remove ring (26) and snap ring (27). 4 Bucket link: 650 kg

3) Remove mounting bolts (17) and washers (18) of cover (19) installed to mounting pin (10) connecting link (3) and bell crank (2), and remove the cover. a When the cover is hard to remove, use the forcing tap to remove it. a Forcing tap: M12 x 1.75 (2 places) a Prepare an oil container since the oil in the mounting pin flows out when the cover is removed.

4) Remove four pin flange fixing bolts (8) and four spacers (9) of mounting pin (10), then pull out mounting pin (10) using special tool T1. 4 Mounting pin: 80 kg a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

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6) 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

3. Removal of pin connecting lift arm and bucket 1) Sling lift arm (1). 4 Lift arm (single unit): 17,850 kg Purpose: To prevent the lift arm from lowering due to its own weight when mounting pin (10) is removed.

2) Remove ring fixing bolts (24) and washers (25) of ring (21) of the joint between bucket (4) and lift arm (1). 7) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

8) Taking the same procedures in Steps 1) to 7), remove the other mounting pin connecting the bell crank and bucket link.

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3) Remove mounting bolts (17) and washers (18) of cover (19) installed to mounting pin (10) connecting bucket (4) and lift arm (1), and remove the cover. a When the cover is hard to remove, use the forcing tap to remove it. a Forcing tap: M12 x 1.75 (2 places) a Prepare an oil container since the oil in the mounting pin flows out when the cover is removed.

5) Taking the same procedures in Steps 1) to 4), remove the other mounting pin connecting the bucket and lift arm. 6) Sling bucket (4) and disconnect it from lift arm (1). 3 4 Standard bucket (20 m ): 21,050 kg

7) Remove ring verticalization bolt (23), ring (21) and snap ring (22). 4) Remove four 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: 170 kg a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

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8) Remove collar A (11) and collar B (12) from bucket (4). 4 Collars A and B (single unit): 22 kg q Length of collar A (11) and collar B (12): 121.8 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

4. Removal of pin connecting bell crank and piston rod of cylinder 1) Insert a block between bell crank (2) and lift arm (1) to fix bell crank (2). k Be sure to fix the bell crank since it comes down when the mounting pin on the bucket cylinder piston rod side is removed. 2) Sling bucket cylinder assembly (6). 4 Bucket cylinder assembly: 1,400 kg

9) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

3) Remove mounting bolts (17) and four washers (18) of cover (19) installed to mounting pin (10) connecting bell crank (2) and piston rod of bucket cylinder (6), and remove the cover. a When the cover is hard to remove, use the forcing tap to remove it. a Forcing tap: M12 x 1.75 (2 places) a Prepare an oil container since the oil in the mounting pin flows out when the cover is removed.

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4) Remove four pin flange fixing bolts (8) and four spacers (9) of mounting pin (10), then pull out mounting pin (10) using special tool T1, and disconnect bell crank (2) from the piston rod of bucket cylinder (6). 4 Mounting pin: 70 kg k Check that the bell crank is fixed since it comes down when the mounting pin is removed. a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

6) 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

7) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12). 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.

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5. Removal of pin connecting bell crank and lift arm 1) Sling bell crank (2). 4 Bell crank: 2,450 kg

3) Remove pin flange fixing bolts (8) and spacers (9) of mounting pin (10), then pull out mounting pin (10) using special tool T2, and disconnect bell crank (2) from lift arm (1). 4 Mounting pin: 170 kg a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

2) Remove four mounting bolts (17) and four washers (18) of cover (19) installed to mounting pin (10) connecting bell crank (2) and lift arm (1), and remove the cover. a When the cover is hard to remove, use the forcing tap to remove it. a Forcing tap: M12 x 1.75 (2 places) a Prepare an oil container since the oil in the mounting pin flows out when the cover is removed.

4) Sling and remove bell crank (2). 4 Bell crank: 2,450 kg 5) Remove collar A (11) and collar B (12) from lift arm (1). 4 Collars A and B (single unit): 22 kg q Length of collar A (11) and collar B (12): 121.8 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 procedure using special tool T4, see "2. How to use collar removal tool" in the "How to use special tools".

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6) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

3) Remove mounting bolts (17) and washers (18) of cover (19) installed to mounting pin (10) connecting lift arm (1) and the piston rod of lift cylinder (5), and remove the cover. a When the cover is hard to remove, use the forcing tap to remove it. a Forcing tap: M12 x 1.75 (2 places) a Prepare an oil container since the oil in the mounting pin flows out when the cover is removed.

7) Taking the same procedure in Steps 1) to 6), disconnect the other pin connecting the bell crank and lift arm. 6. Removal of pin connecting lift arm and piston rod of lift arm cylinder 1) Fix lift arm (1).

2) Sling lift cylinder assembly (5). 4 Lift arm cylinder assembly: 2,950 kg

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4) 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 a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

6) Remove collar A (11) and collar B (12) from lift arm (1). q Length of collar A (11) and collar B (12): 101.8 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 procedure using special tool T4, see "2. How to 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 front axle (35) to fix lift arm cylinder (5).

7) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12). a Dust seal (15) is installed to the machine with serial number 50077 and up.

8) Taking the same procedure in Steps 2) to 7), remove the other pin connecting the lift arm and piston rod of the lift arm cylinder.

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7. Removal of lift arm angle sensor 1) Remove cover (36). 2) Remove lever(37). 3) Disconnect wiring harness connector F04 (38) and remove clamp (39). 4) Remove lift arm angle sensor (41).

3) Remove mounting bolts (17) and washers (18) of cover (19) installed to mounting pin (10) connecting lift arm (1) and front frame (7), and remove the cover. a When the cover is hard to remove, use the forcing tap to remove it. a Forcing tap: M12 x 1.75 (2 places) a Prepare an oil container since the oil in the mounting pin flows out when the cover is removed.

8. Removal of pin connecting lift arm and front fame 1) Check that lift arm (1) is fixed. 4) Remove four 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: 230 kg a For the mounting pin removal procedure, see "1. How to use work equipment pin removal tool" in the "How to use special tools".

2) Sling lift arm (1). 4 Lift arm (single unit): 17,850 kg

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5) Remove collar A (11) and collar B (12) from front frame (7). 4 Collars A and B (single unit): 40 kg q Length of collar A (11) and collar B (12): 174.7 mm a If collars A and B are hard to remove, use special tool T5 to remove them. a For the collars A and B removal procedure using special tool T5, see "2. How to use collar removal tool" in the "How to use special tools".

7) Taking the same procedure in Steps 3) to 6), remove the other pin connecting the lift arm and front frame. 8) Remove lift arm (1) 4 Lift arm: 17,850 kg

6) Remove bushing seal assembly (14), dust seal (15) and collar O-ring (16) from collar A (11) and collar B (12).

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 bushing (13) at four places to remove it. a Take care not to melt bushing boss (13A) in gas cutting.

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Outline of shim selection for installing mounting 50-357 pin (Outline of shim adjustment procedure) 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)

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.

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

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Collar end face shim: Installed to the collar end face Available shims: 0.3 mm and 0.5 mm (two types)

Pin end face shim: Installed to the pin end face Available shims: 0.3 mm and 0.5 mm (two types)

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4. List of part numbers of shims used for each part

Shim installed position Joint between lift arm and bucket Joint between bucket and bucket link Joint between bell crank and bucket link Joint between bell crank and piston rod of bucket cylinder Joint between bucket cylinder bottom and front frame Joint between lift arm and bell crank Joint between lift arm and piston rod of lift arm cylinder Joint between lift arm cylinder bottom and front frame Joint between lift arm and front frame Pin diameter (mm) f240 f180 f180 f180 f180 f240 f240 f240 f280 Shim thickPart number of pin ness flange shim (mm) 0.5 42C-70-12920 0.3 0.5 42C-70-12910 0.3 0.5 42C-70-12910 0.3 0.5 42C-70-12910 0.3 0.5 42C-70-12910 0.3 0.5 42C-70-11920 0.3 0.5 42C-70-12920 0.3 0.5 42C-70-12930 0.3 0.5 42C-70-12940 0.3 Part number of collar end face shim 42C-70-11880 42C-70-11780 42C-70-11870 42C-70-11770 42C-70-11870 42C-70-11770 42C-70-11870 42C-70-11770 42C-70-11870 42C-70-11770 42C-70-11880 42C-70-11780 42C-70-11880 42C-70-11780 42C-70-11880 42C-70-11780 42C-70-11890 42C-70-11790 Part number of pin end face shim 42C-70-11840 42C-70-11830 42C-70-11860 42C-70-11850 42C-70-11860 42C-70-11850 42C-70-11860 42C-70-11850 42C-70-11860 42C-70-11850 42C-70-11840 42C-70-11830 42C-70-11840 42C-70-11830 42C-70-11840 42C-70-11830 42C-70-11820 42C-70-11810

5. Selection procedure of shims used (types and thicknesses of shims) 1) Install tool T15 (fixing plate used when press fitting the bushing) to bushing boss (13A) and press fit bushing (13) to bushing boss (13A). Reference: The portion to which the bushing is press fitted is referred to as "bushing boss". a For the press fitting procedure of the bushing, see Installation, "2 Installation (press-fit) of bushing to bushing boss".

2) Insert collar A (11) and B (12) to collar boss A (11A) and B (12A). Reference: The portion to which the collar is installed is referred to as "collar boss". a Do not install the bushing seal assembly, collar O-ring and dust seal to collar A (.11) and collar B (12). 3) Install bushing boss (13A) and do center alignment of bushing (13) with collar A (11) and B (12). a When installing bushing boss (13A), keep collar A (11) and B (12) 10 mm out of the collar boss.

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4) Fix collar A (11) (collar on the pin flange side) using pin flange fixing bolts (8) and spacers (9).

5) Collar B (12) must be against bushing (13). Install fixing tool T10, T11, or T12 (collar stopper plate) to collar B (12) using T14 (plate mounting bolt). Then screw in T13 (collar tap bolt) to push collar B (12) toward bushing (13) until the tightening torque becomes large (bushing (13) is in close contact with collar 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".

6) Push the end face of collar A (11) inward to make its face contact bushing (13), then 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 bushing (13). a In order to avoid confusion in the measured results, attach the travel signs of + (plus) or - (minus) as shown below to the measured "dimension a" as well as "dimension b" and "dimension c" that are to be measured in the succeeding steps. Above symbols + and - represent the dimensional difference with the collar end face and collar boss end face. a For dimension a When collar A (11) is outside end face of collar boss A (11A): -a1 (- indication) When collar A (11) is inside end face 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)

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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: Dimension a -0.5 (an appropriate clearance between 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 dimension a)

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9) Remove pin flange fixing bolts (8) and spacers (9), then loosen tool T13 (collar tap bolt) sufficiently to move collar A (11) and collar B (12) 10 mm apart from the collar boss. Then remove the bushing boss from the collar bosses once. 10)Install bushing seal assembly (14), collar O-ring (16) and dust seal (15) to collar A (.11) and collar B (12). 11)Install bushing boss (13A) and do center alignment of bushing (13) with collars A (11) and B (12), then insert mounting pin (10) to collar A (11). a When installing bushing boss (13A), keep collar A (11) and B (12) 10 mm out of the collar bosses.

12)Fix mounting pin (10) using pin flange fixing 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".

13)Measure "dimension a" and "dimension b" again in the same positions as that used in steps 6) and 8) and note the measurements in Attached Table 1. a "Dimension a" and "dimension b" obtained in this measurement should be almost the same as "dimension a" and "dimension b" obtained in steps 6) and 8) respectively. If a large difference (4 to 5 mm or greater) is found between them, bushing seal assembly (14) fitted to the side face of collars A (11) and B (12)are probably out of position. The above measurement is to finally check that bushing seal assembly (14) is fitted in position respectively. a "Dimension a" and "dimension b" obtained in this Step 13) may not be identical to "dimension a" and "dimension b) obtained in Steps 6 and 8), and "corrected 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 collar boss A (11A) (-a1 indication)

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When collar A (11) is inside the end face of collar boss A (11A) (+a2 indication)

14)Measure the travel of collar B (12) with 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 measuring "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)

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15)Determine the type and numbers of the shims for collar A (11) from "dimension a" or "corrected dimension a" in Attached Table 1 to provide an appropriate clearance (0.5 to 0.7 mm) between bushing (13) and collar A (11). a Note that the shim pack for the end face of collar A (11) is already installed in step 7). 16)Determine the type and numbers of the shims for collar B (12) from "dimension c" in Attached Tables 1 and 2 to provide an appropriate clearance (0.5 to 0.7 mm) between bushing (13) and collar B (12). a In this case, note that the installed position of mounting pin (10) is finally displaced by the thickness of shim pack for the pin flange of collar A (11). 17)Remove pin flange mounting bolts (8), spacers (10) and tools (such as collar stopper plate and collar tap bolt) T10, T11, T12, T13 and T14 on collar A (11) side.

18)Prepare shim packs finally used and install them to the necessary portions (collar A side and collar B side) to perform the final assembling. <Reference 1> q If, for instance, the final travel of collar A (11) with respect to collar boss A (11A), that is "dimension a" or "correction of dimension a", is +0.15 mm (collar A (11) is inside collar boss A (11A)), adjusting the clearance between collar A (11) and bushing (13) to 0.5 mm theoretically requires to move collar A (11) (= pin flange position) 0.35 mm (0.15 mm - 0.5 mm) outside. To that end, the mounting pin installed position (= pin flange position) must be moved 0.35 mm outside (installation of shims for the pin flange). q The minimum pin flange shim thickness beyond 0.35 mm is a single 0.5 mm thick shim. a Theoretically, the clearance between collar 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 inside 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 mounting pin tip with respective to collar B (12) is 2.3 mm (1.8 mm + 0.5 mm). The minimum thickness of the pin tip face shim beyond 2.3 mm is provided by four 0.5 mm shims and a 0.3 mm shim. a Theoretically, the clearance between collar 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.)

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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) 8) Installation of bucket link to bucket (right and left sides) a Check the parts assembled for scratches and dents, then remove soil, dirt and stains on the coating. a Eliminate rusts, if any. a When you have replaced mounting pin (10), chamfer "a" portion in the shaft tip to make it smooth.

2) Cool bushing (13) using liquid nitrogen for 60 minutes or more. 3) After cooling bushing (13) with liquid nitrogen, insert it to bushing boss (13A). a Be sure not stop insertion work halfway. If you stop the operation halfway, the bushing becomes immovable and you have to remove it. a After inserting the bushing, check both 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 assembling. 1) Install special tool T15 (fixing plate used when press fitting the bushing) to bushing boss (13A). Reference: The portion to which the bushing is press fitted is referred to as "bushing 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 cannot be installed (locations for bushings such as the bushing for lift arm cylinder and bushing for bucket cylinder).

a The following describes the installation procedures of the typical connecting parts.

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3. Temporary insertion of collars A and B to the collar boss Purpose: To measure travel of collars A (11) and B (12) with respect to end face of collar bosses A (11A) and B (12A) for adjustment with shims. a Do not install the bushing seal assembly, dust seal and collar O-ring to collar A (.11) and collar B (12). a If collar A (11) or B (12), and collar boss A (11A) or B (12A) is rusted, remove the rusts using sandpaper and such. Remove attached 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: Molybdenum disulphide lubricant (LM-P) 2 Periphery of collar: Molybdenum disulphide lubricant (LM-P) a Apply as much lubricant as possible to the inside of the collar boss. a Apply lubricant with your hands without using a brush. Do not use a brush since its bristles can adhere to the collar or collar boss.

2) Insert collar A (11) and collar B (12) to collar boss A (11A) and B (12A). 3) Put the inner end face of collar A (11) and B (12) approximately 10 mm out of the inner face of collar boss A (11A) and B (12A). Purpose: To prevent interference between the collar and bushing boss when inserting the bushing boss between the collar bosses.

4. Center alignment of collars A and B and bushing a As for a position where the dirt intrusion prevention ring is installed, install the dirt intrusion prevention ring to the bushing boss first, then install the bushing boss between the collar bosses. For details, see "14 Installation of dirt intrusion prevention ring". 1) Sling bushing boss (13A) using a crane and install it between collar boss A (11A) and B (12A).

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2) Align the center of collars A (11) and B (12) and bushing (13). a Check that collars A (11) and B (12) do not contact bushing boss (13) but are in close contact with bushing (13) when they are pushed toward bushing (13).

5. Fixing of collars A and B from both sides of collar boss 1) Push in collar A (11) toward bushing (13), then fix collar A (11) using pin flange fixing bolts (8) and spacers (9) to make collar A (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 horizontal fixing of the dirt intrusion prevention ring and washer. q Tool T10: For pin of f180 mm q Tool T11: For pin of f240 mm q Tool T12: For pin of f280 mm

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a There are three approaches A, B and C in installing the collar stopper plate of tools T10, T11 and T12. For details, see "4. Attached tools (collar stopper plate) installation procedure" in "How to use special tools".

4) Check that clearance (a) is not left. The clearance can be left if collar A (11) is inside the outer end face of collar boss A (11A). Purpose: If clearance (a) is left, a clearance results between collar A (11) and 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), then fix it firmly by tightening it using tool T13 (collar tap bolt).

6. Measurement and note of travel of collars A and B a This dimension measurement is important to the determination of the shim installation positions 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 periphery of the collar boss end face is not machine-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 instrument and do the measurement in the following manner.

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1) Note of travel of collar A (11) with respect to collar boss A (11A) Note the measurement as "dimension a" in No.1.1 of Attached Table 1. a In many cases, the standard dimension (dimension a) of collar A is almost 0 mm. : Note "value of almost 0" as "-a11 dimension" a When collar A (11) is outside the outer end face of collar boss A (11A): Note the measurement as "-a11 dimension".

2) Note of travel of collar B (12) with respect to collar boss B (12A) Note the dimension as "dimension b" in No.1.1 of Attached Table 1. a When collar B (12) is outside the outer end face of collar boss B (12A): Note the value as "-b11 dimension".

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 inside (to the bushing), it can enter inside the outer end face of collar boss A (11A) though rarely. : Note the value as "+a21 dimension".

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7. Preparation for insertion of pin 1) Remove pin flange fixing bolts (8) and spacers (9) that are fixing collar A (11). 2) Loosen tool T13 bolt that is fixing collar B (12), remove tool T14 fixing bolt and remove tool T10, T11, or T12 from the collar boss once.

5) Clean the inner surface and side face of collar A (11) and B (12) using a piece of cloth and apply a large volume of gear oil. 2 Collars A and B (inner surface and side face): Gear oil (GL-5) a It is allowed to do the same work with collars A and B removed from respective collar 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 of the collar bosses A and B to prevent interference with the collars A and B.

a Handle floating seal (14-1) and square ring (14-2) that consist of bushing seal assembly (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 direction of the square ring.

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7) Install bushing seal assembly (14), dust seal (15) and collar O-ring (16) to collars A (.11) and B (12). a In this step, be sure not to allow adhesion of foreign substances such as sands.

a Take care not to install collar O-ring (16) twisted. a Take care not to install dust seal (15) facing wrong direction when installing it to 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 acceptable as the installation timing.

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a When installing bushing seal assembly (14), install floating seal (14-1) and square ring (14-2) with care so that they are fitted in position. And take care not to install bushing seal (14) facing wrong direction. Floating seal (14-1): Outside (bushing side) Square-ring (14-2): Inside

8) After installing bushing seal (14) to collars A (11) and B (12), put collars A (11) and B (12) 10 mm out of collar bosses A (11A) and B (12A) to prevent bushing seal assembly (14) protruding out of the end face of collar bosses A (11A) and B (12A). Purpose: To prevent interference between the bushing seal assembly and the 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): Molybdenum disulphide lubricant (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)

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a If lubricant (LM-P) is excessive, lubricant (LM-P) can mix with gear oil in mounting pin (10) while the machine is operation. And the resulting sediments (D) of lubricant can clog gear oil lubricating hole (C) of mounting pin (10), blocking circulation of gear oil. Thus, you must not apply an excessive volume of lubricant. A: Oil level B: Oil circulation path C: Oil circulation hole D: Sediments of lubricant that cloggs the oil circulation hole

11)If end face of collar A (11) is found to be inside the collar boss in step 6 "Measurement and note of travel of collars A and B", select the thickness and numbers of collar end face shims (31) and the numbers of pin flange shims in such that they coincide with the shim thickness obtained by subtracting the clearance (0.5 to 0.7 mm) between collar A and bushing from +a2 dimension. Then apply oil to the collar end face shims and install them to the mounting pin (10) beforehand.

10)Check mounting pin (10) and inside hole of the pin for adhesion of sands and rusts. And eliminate them, if any. a Particular attention is required to the inside of the hole at the center of the pin in which sands and rusts tend to adhere. (If rusts are gathered, remove them using a sandpaper.)

a After installing the collar end face shims to the mounting pin, note the shim thickness and number of shims used, and also calculate and note "dimension a" after insertion of the shims in No.1.2 of Attached Table 1. q Note the thickness and numbers of the installed collar end face shims, and also note the total shim pack thickness. q "Dimension a" after collar end face shims are inserted to pin: Note the value 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 bushing 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 bushing becomes 0.5 mm.

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12)Tie mounting pin (10) with belt [1] and sling it using a crane. k Pay attention to the balance after tying with the belt. 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 using a brush (bristles may adhere to them).

Type B: Installing mounting pin (10) equipped with collar A (11) at its tip to collar boss A (11A) after removing collar A (11) once from collar boss A (11A).

8. Installation of pin to collar A The following lists different approaches employed when installing the pin. Type A: Installing mounting pin (10) to collar A (11) while leaving collar A (11) installed to collar boss A (11A).

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 another 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 bushing (13), collar A (11) is inserted to collar boss A (11A). In this case, however, confirmation of detachment of bushing seal assembly (14) becomes unavailable when inserting collar A (11) to collar boss A (11A). Therefore, this approach must not be employed.

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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 selected in step 7-11), install it to the mounting pin beforehand. 2] When the tip of mounting pin (10) came near to the inner end face of collar A (11), stop the installation once. a At this point, collar A (11) may be pushed to move by mounting pin (10) and, as a result, bushing seal (14) installed to collar A (11) can jump out of 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 beforehand.

a To prevent bushing seal assembly (14) from jumping out of the inner end face of respective collar bosses A (11A) and B (12A), position collars A (11) and B (12) 10 mm out of the inner end face of the respective collar bosses in advance.

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9. Final center alignment of collars A and B and bushing 1) When installing mounting pin (10), to prevent collar B (12) from being moved to the outside by mounting pin (10), install any of the collar stopper plates of special tool T10, T11, or T12 to collar B (12) using tool T14 bolt. Then install tool T13 bolt. q Tool T10: For pin of f180 mm q Tool T11: For pin of f240 mm q Tool T12: For pin of f280 mm a There are three approaches, A, B and C types, in installing the collar stopper plate of tools T10, T11 and T12. For details, see "4. Attached tools (collar stopper 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 install it between collar boss A (11A) and B (12A).

5) Perform center alignment of collars A (11) and B (12) with bushing (13) placing a person for confirming the center alignment in a position opposite to mounting pin (10) installation side (collar B (12) side). k Use a rod and such for this center alignment. Be sure not to insert your fingers into the holes. 6) After checking that collars A (11) and B (12) do not touch bushing boss (13A), push collars A (11) and B (12) toward bushing (13) with your hands. a Push them carefully so that bushing seal assembly (14) are not out of position. 7) Push collar B (12) using tool T13 bolt.

8) Supply a large volume of gear oil to busing (13) and collar B (12) using cups [2], then 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. Therefore, 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.

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After a large volume of gear oil is applied

10. Final installation of pin 1) Check the center alignment again to make sure that the center of bushing boss (13A) and that of collars A (11) and B (12) are not misaligned. k Whenever center alignment is needed, use a rod and such without inserting your fingers into the holes. 2) Push mounting pin (10) at a breath until it passes collar O-ring (16) and dust seal (15) of collar B (12). a Dust seal (15) is installed to the machine with serial number 50077 and up. a Install mounting pin (10) with its oil holes (f) in vertical direction. a When diameter of the mounting pin is large (240 or 280 mm), it must be pushed by a pair of workers from the start because it requires large insertion force. a If you stop insertion of mounting pin (10) halfway, center alignment is lost and the pin insertion force can be increased. Therefore, you must insert it at a breath at least up to a position near collar B (12) 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

a Do not strike mounting pin (10) with a hammer to insert. You must refrain from such practice to prevent detachment of bushing seal (14), that is installed to collar A (11) and B (12), and forcible insertion of the mounting pin. a If mounting pin (10) is stopped halfway through bushing (13) and remains there immovable with hands, align the center of collar B (12) and bushing (13) using the crane without trying to forcibly inserting it by use of a special tool. Then insert the mounting pin with hands again. a When you pull mounting pin (10) out of bushing (13) once to align the center of collars A (11) and B (12) with bushing (13), collar A (11) may move to the outside along with the movement of mounting pin (10) under the pulling force and, as a result, detachment of bushing seal assembly (14) on collar A (11) from the groove can occur. Therefore, you must first prevent outward-movement of collar A (11) by fixing it with the pin flange fixing bolt and spacer and then pull out mounting pin (10).

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3) Fix mounting pin (10) using pin flange fixing bolt (8) and spacer (9) securely. 4) Using tool T13, push collar B (12) toward bushing (13) and fix it.

5) Remove the belt of the crane slinging bushing boss (13A). 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".

Purpose: Travel of collar A is measured in the above step 6-1) and the shims necessary 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 protrusion out of collar boss A. However, since collar A is hidden by the flange of the mounting pin and direct measurement is unavailable. Therefore, the clearance between the mounting pin flange and the mounting surface on collar boss A is measured 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 damaged. In this case, pull out the mounting pin once and replace the bushing seal assembly with a new one. 2 Bushing seal assembly: Gear oil (GL-5) a After pulling out the mounting pin, repeat the work from step 9 "Final center alignment of collars A and B and bushing".

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

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Collar B is inside the end face of collar boss B : 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 maintained 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 to collar B may be out of position or damaged. In this case, remove the tool (collar stopper plate), pull out collar B and replace the bushing seal assembly with a new one. 2 Bushing seal assembly: Gear oil (GL-5) a Install collar B again slowly, install the tool (collar stopper plate) and, using tool T13 bolt, push collar B toward the bushing and fix it. Then measure travel of collar B again. a Result of the re-measurement conducted on the travel of collar B may deviate 1 to 2 mm from the measurement in the previous 6-2), but you can ignore it since the deviation can be regarded as within the measurement error. (In this case, the above value is used as the final "dimension b". q When collar B (12) is outside collar boss B (12A)
q

When collar B (12) is inside collar boss B (12A)

3) Measure "dimension c", that is the travel of collar B (12) with respect to the tip of mounting pin (10), and note it in No.1.3 of Attached Table 1. a In order to avoid confusion in the measured results, attach the travel symbols + (plus) or - (minus) representing the travel of collar B end face with respect to the mounting pin end face (tip) to the measured "dimension c" as shown below. q When the end face of mounting pin is outside collar B: Note the value as "-c13 dimension". q When the end face of mounting pin is inside collar B: Note the value as "+c23 dimension". Purpose: To determine the thickness of the collar end face shims or pin end face shims to be installed to collar B. a The above measurement must be done in the same or near the position where measurement 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)

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When tip of mounting pin is inside collar B (12)

6) Select the types (collar end face shim, pin 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 originally installed. a Do not leave the mounting bolt hole in tools T10, T11 and T12 without the bolt since the holes are rusted and eroded and further use is disabled. Be sure to install tool T14 (including washer) to them.

12. Calculation of necessary shim pack thickness based on each dimension measurement a Calculate the necessary shim pack thickness 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 No.2.1 of Attached Table 2. a See Attached Tables 4-1 and 4-2. 3) Determine the necessary numbers of pin flange shims from calculation of above 2) and note it in No.2.2 of Attached Table 2. a Available thickness of the pin flange shim is 0.5 mm alone. a See Attached Tables 4-1 and 4-2. 4) Assuming that shims are inserted to collar A (11), re-calculate "dimension c", that is the travel of the tip of mounting pin (10) with respect to collar B (12), and note it in No.3.1 of Attached Table 2. a See Attached Tables 4-3 and 4-4. 5) Taking into consideration the mounting pin is moved in above Step 4), calculate the thickness 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.

3) Prepare shims necessary for collar A (11) and collar B (12), remove stains on them and apply a thin film of oil to them. a Prepare shims for the pin flange at this point. 4) Install shims to collar A (11) and pin flange shims (30) to the flange of mounting pin (10) and fix them using pin flange fixing bolts (8) and spacers (9). a When the lift arm cylinder bottom is disconnected from the front frame, install the shims for the pin flange to the top and bottom in accordance with machined surface (1A) on the front frame. The positions of pin flange mounting bolts for front fame (1) are the same in the top and bottom, and right and left.

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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 q Joint between bell crank and bucket link q Joint between bucket and bucket link 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) 7) Install cover (19) to the tip of mounting pin (10), install cover mounting bolts (17) and washer (18) and tighten them to the specified torque. 8) Tighten pin flange fixing bolts (8) to the specified torque. 3 Pin flange fixing bolt M24: 824 to 1,030 Nm {84 to 105 kgm} M30: 1,5201,910m {155195 kgm}

2] Place snap ring (22) in the snap ring groove on top and bottom dirt intrusion prevention rings (21), and install top and bottom dirt intrusion prevention rings (21) to lift arm (1).

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3] Connect top and bottom dirt intrusion prevention rings (21) using top and bottom ring fixing bolts (23) and tighten the bolts to the specified torque. 3 Top and bottom ring fixing bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

2) Joint between bell crank and bucket link and joint between bucket and bucket link 1] Install snap ring (27) to bucket link (3). 2] Place snap ring (27) in the snap ring groove on dirt intrusion prevention ring (26).

4] Install the bushing boss between the collar bosses and, after the center alignment is over, push dirt intrusion prevention ring (21) toward the bucket side. a After the installation is finished, install ring horizontalization bolt (24) and washer (25) and tighten it to the specified torque. 3 Ring horizontalization bolt: 98 to 123 Nm {10.0 to 12.5 kgm}

3] Install the bushing boss between the collar bosses and, after the center alignment is over, push dirt intrusion prevention ring (26) toward the bucket or bell crank side. a After the installation is finished, install ring horizontalization bolt (28) and washer (29) and tighten it to the specified torque.

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Work equipment Removal and installation of work equipment assembly

15. Refilling of gear oil to work equipment pin a High viscosity oil must be used in hot regions. q See step 22 "Introduction of high viscosity oils". a Since high viscosity oil is hard and difficult to supply warm it to soften before refilling. a Since high viscosity oil is hard and oil level does not become horizontal soon, you must recheck the oil level again in about 8 hours from the refilling. 1) Tighten lower gear oil drain plug (34) installed to mounting pin (10) and remove upper gear oil filler plug (33). 2) Supply gear oil from the oil filler plug hole until oil flows out of the hole. 5 Mounting pin: Gear oil (GL-5) (refilling) 3) Install oil filler plug (33) again. 4) Clean attached oil.

16. Installation of other work equipment joints a Perform installation of the remaining joints in the same procedure as described in steps 2 to 15. 17. Adjustment of lift arm levelness detection switch a Adjust the proximity switch. For details, see Testing and adjusting, "Adjustment of lift arm levelness detection switch". 18. Adjustment of lift arm potentiometer a Adjust the lift arm potentiometer. For details, see Testing and adjusting, "Adjustment of lift arm potentiometer". 19. Refilling a Start the engine, circulate hydraulic oil in hydraulic cylinder, piping, and hoses, and supply oil through the hydraulic tank oil filler to the specified level. 20. Air bleeding Bleed air from the hydraulic circuit. For details, see "Bleeding air from work equipment circuit and steering circuit". 21. Running in a Perform running-in operation. For details, 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 necessary for a machine. q And when ordering a machine that uses the oil for hot regions, select the sales code "6ZZ61A".

WA1200-6

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Work equipment Removal and installation of work equipment assembly

Attached Table 1 Note for travel of collars A and B and mounting pin tip 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 distance Inside the Display the collar from collar Display the collar from inside collar boss boss inside to boss boss to outside outside -a1 +a2 -b1 +b2 mm mm -a11 +a21 mm mm mm mm -b11 +b21 mm mm mm mm mm mm

50-384

No.

Content

Measurement indication Measurement (right 6-1) and and left) 1.1 2) Before Measurement (top (Step pin inser- and bottom) 1) tion Mean An appropriate clearance between collars A, B and bushing

0.50.7 mm pieces

7-11) Immedi1.2 ately (Step before 2) pin insertion

11-1) and 1.3 2) After (Step pin inser3) tion

Numbers of 0.5 mm Selection of shims shims for collar end face Numbers when collar A is of 0.3 mm inside collar boss A shims Total shim thickness Travel after shims for collar end face +a22 are inserted to pin Measurement (right and left) Measurement (top and bottom) -a13 Mean +a23

pieces mm mm mm mm mm mm mm mm mm -b13 +b23 mm mm mm mm mm mm

No.

Content

Measurement indication Measurement 11-3) (right and left) After Measurement 1.3 pin (top and bot(3step) inser- tom) tion Mean

Travel of pin with respect to collar B Moving disOutside the tance from Inside the Display collar boss inside to collar boss outside -c1 +c2 mm mm -c13 +c23 mm mm mm mm

50-384

WA1200-6

Work equipment Removal and installation of work equipment assembly

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 Moving disOutside the tance from Inside the No. Content Display collar boss inside to collar boss 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 A2 +a23 - 0.5 +a23 - 0.5 shims are not assumed in 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 necesshims for pin flange that exceed A1 dimensary sion 2.2 12-3) Quantity of 0.5 mm pieces pieces Final thickness of shims Total shim shims for pin A mm mm thickness flange 3 Calculation of shims for collar B end face and shim thickness for pin end face Travel of pin end face with respect to collar B Moving Outside distance Inside the Display the collar B from inside collar B to outside

12-4), 5) Theoretical calcula3.1 tion

Precautions for selection of shims for pin flange 3.2 12-6) Final thickness of collar end face shims and pin end face shims Types of shims: Number of shims Total shim thickness

Set an optimum clearance between 0.5 and 0.7 mm first, then insert shims for collar end face and shims for pin flange. =-c13 + A c1 + 0.5 =-c13 + A =+c23 + A c2 + 0.5 + 0.5 The maximum thick- The minimum thickness ness of collar end face of pin end face shims shims that does not that exceeds C2 dimenexceed C1 dimension sion Shim for collar end Shim for pin end face face 0.3 mm pieces pieces pieces 0.5 mm pieces pieces pieces c mm mm mm

WA1200-6

50-385

Work equipment Removal and installation of work equipment assembly

Attached Table 3 Part numbers of shims used for each part

Shim installation position Joint between lift arm and bucket Joint between bucket and bucket link Joint between bell crank and bucket link Joint between bell crank and piston rod of bucket cylinder Joint between bucket cylinder bottom and front frame Joint between lift arm and bell crank Joint between lift arm and piston rod of lift arm cylinder Joint between lift arm cylinder bottom and front frame Joint between lift arm and front frame Pin diameter (mm) f240 f180 f180 f180 f180 f240 f240 f240 f280 Shim thickness (mm) 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 0.5 0.3 Shim part number for pin flange 42C-70-12920 42C-70-12910 42C-70-12910 42C-70-12910 42C-70-12910 42C-70-11920 42C-70-12920 42C-70-12930 42C-70-12940 Shim part number for collar end face 42C-70-11880 42C-70-11780 42C-70-11870 42C-70-11770 42C-70-11870 42C-70-11770 42C-70-11870 42C-70-11770 42C-70-11870 42C-70-11770 42C-70-11880 42C-70-11780 42C-70-11880 42C-70-11780 42C-70-11880 42C-70-11780 42C-70-11890 42C-70-11790 Shim part number for pin end face 42C-70-11840 42C-70-11830 42C-70-11860 42C-70-11850 42C-70-11860 42C-70-11850 42C-70-11860 42C-70-11850 42C-70-11860 42C-70-11850 42C-70-11840 42C-70-11830 42C-70-11840 42C-70-11830 42C-70-11840 42C-70-11830 42C-70-11820 42C-70-11810

50-386

50-386

WA1200-6

Work equipment Removal and installation of work equipment assembly

Attached Table 4-1 Selection of shims for collar A side (pin flange side) collar end face
1.1 (1 step), 6-1 and 2) Travel of collar A with respect to collar boss A (before pin insertion) -0.7 mm -0.6 mm -0.5 mm -0.4 mm -0.3 mm -0.2 mm -0.1 mm 0 mm +0.1 mm +0.2 mm +0.3 mm +0.4 mm +0.5 mm +0.6 mm +0.7 mm +0.8 mm +0.9 mm 1.2 (2 step), 7-11) Shim thickness on collar A side (shim for collar After shims are end face) inserted Number of Type Total thickness (+a22) shims -0.7 mm -0.6 mm -0.5 mm -0.4 mm -0.3 mm -0.2 mm -0.1 mm 0 mm +0.1 mm +0.2 mm 0.3 mm 1 0.3 mm 0 mm 0.3 mm 1 0.3 mm -0.1 mm +0.5 mm +0.6 mm +0.7 mm 0.3 mm 1 0.3 mm +0.5 mm 0.3 mm 1 0.3 mm +0.6 mm Remarks Appropriate clearance between collar A and bushing: 0.5 to 0.7 mm.

50-387

a11

See Fig. 1

+a21

See Fig. 2

Fig. 1

Fig. 2

WA1200-6

50-387

Work equipment Removal and installation of work equipment assembly

Attached Table 4-2 Selection of shims for pin flange

1.3 (3 step), 11-1) and 2) Measured travel of collar A with respect to collar boss A (after pin insertion) -0.9 mm -0.8 mm -0.7 mm -0.6 mm -0.5 mm -0.4 mm -0.3 mm -0.2 mm -0.1 mm 0 mm +0.1 mm +0.2 mm +0.3 mm +0.4 mm +0.5 mm +0.6 mm +0.7 mm Appropriate clearance 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm Targeted shim thickness = -a13 - 0.5 or =+a23 - 0.5 (-1.4 mm) (-1.3 mm) (-1.2 mm) (-1.1 mm) (-1.0 mm) (-0.9 mm) (-0.8 mm) (-0.7 mm) (-0.6 mm) (-0.5 mm) (-0.4 mm) (-0.3 mm) (-0.2 mm) (-0.1 mm) (0 mm) (+0.1 mm) (+0.2 mm) Collar A side shim thickness (shims for pin flange) Type 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm

50-38
Remarks

a13

+a23

Clearance after shims Appropriate clearPin movare inserted ance between coling disNumber of Total thick- (between lar A and bushing: tance shims ness collar A and 0.5 to 0.7 mm. bushing) 3 1.5 mm 0.6 mm 0.6 mm 3 1.5 mm 0.7 mm 0.7 mm 3 1.5 mm 0.8 mm 0.8 mm 3 1.5 mm 0.9 mm 0.9 mm 2 1.0 mm 0.5 mm 0.5 mm See Fig. 3 2 1.0 mm 0.6 mm 0.6 mm 2 1.0 mm 0.7 mm 0.7 mm 2 1.0 mm 0.8 mm 0.8 mm 2 1.0 mm 0.9 mm 0.9 mm 1 0.5 mm 0.5 mm 0.5 mm 1 0.5 mm 0.6 mm 0.5 mm 1 0.5 mm 0.7 mm 0.5 mm 1 0.5 mm 0.8 mm 0.5 mm 1 0.5 mm 0.9 mm 0.5 mm See Fig. 4 0 mm 0.5 mm 0 mm 0 mm 0.6 mm 0 mm 0 mm 0.7 mm 0 mm

Fig. 3

Fig. 4

50-388

WA1200-6

Work equipment Removal and installation of work equipment assembly

Attached Table 4-3 Selection of shims for collar B side (shims for pin end face) collar end face
1.3 (3 step), 11-3) Shim thickness on collar B side (shim for collar end face) Targeted thickness (shim for pin end face) Shim for collar end face after pin is moved =- c13 + 0.5 + A Total Number Number (* When A = 0 mm) Type Type thickness of shims of shims -1.2 mm -1.1 mm -1.0 mm -0.9 mm -0.8 mm -0.7 mm -0.6 mm -0.5 mm -0.4 mm -0.3 mm -0.2 mm -0.1 mm 0 mm 0.3 mm 0.3 mm 0.3 mm 0.3 mm 0.3 mm 0.3 mm 0.3 mm 0.3 mm 4 2 3 1 2 2 1 1 Shim for pin end face 0.5 mm 0.5 mm 0.5 mm 0.5 mm 1.2 mm 1.1 mm 1.0 mm 0.9 mm 0.8 mm 0.6 mm 0.6 mm 0.5 mm 0.3 mm 0.3 mm 0 mm 0 mm 0 mm Remarks Clearance after shims Appropriate are clearance inserted between collar B (between and bushing: collar B 0.5 to 0.7 mm. and bushing) 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.6 mm 0.5 mm See Fig. 5 0.5 mm 0.6 mm 0.5 mm 0.7 mm 0.6 mm 0.5 mm Clearance after shims are inserted (between collar B and bushing) 0.7 mm 0.6 mm 0.5 mm 0.6 mm 0.5 mm

50-389

Measured pin tip dimension that is outside the collar B

Appropriate clearance

-c13

-1.7 mm -1.6 mm -1.5 mm -1.4 mm -1.3 mm -1.2 mm -1.1 mm -1.0 mm -0.9 mm -0.8 mm -0.7 mm -0.6 mm -0.5 mm

0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm

1 2 1 1

Type

Number of shims

Type

Total Number thickness of shims

-0.4 mm -0.3 mm -0.2 mm -0.1 mm 0 mm

0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm

+0.1 mm +0.2 mm +0.3 mm +0.4 mm +0.5 mm

0.3 mm 0.3 mm 0.3 mm

1 1 1 0.5 mm 0.5 mm 1 1

0.3 mm 0.3 mm 0.3 mm 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 Removal and installation of work equipment assembly

Attached Table 4-4 Selection of shims for pin end face

Measured pin tip Appropridimension that is ate clearoutside the collar B ance +0.1 mm +0.2 mm +0.3 mm +0.4 mm +0.5 mm +0.6 mm +0.7 mm +0.8 mm +0.9 mm +0.10 mm +0.11 mm +0.12 mm +0.13 mm +0.14 mm +0.15 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 1.3 (3 step), 11-3) Remarks Shim thickness on collar B side Clearance after Appropriate Targeted thickness (shim for pin end face) shims are clearance after pin is moved Numinserted between collar B Number Total = +c23 + 0.5 + A Type Type ber of (between collar and bushing: 0.5 of shims thickness (* When A = 0 mm) shims B and bushing) to 0.7 mm. +0.6 mm 0.3 mm 2 0.6 mm 0.5 mm +0.7 mm 0.3 mm 1 0.5 mm 1 0.8 mm 0.6 mm +0.8 mm 0.3 mm 1 0.5 mm 1 0.8 mm 0.5 mm +0.9 mm 0.3 mm 3 0.9 mm 0.5 mm +0.10 mm 0.5 mm 2 1.0 mm 0.5 mm +0.11 mm 0.3 mm 2 0.5 mm 1 1.1 mm 0.5 mm +0.12 mm 0.3 mm 1 0.5 mm 2 1.3 mm 0.5 mm +0.13 mm 0.3 mm 1 0.5 mm 2 1.3 mm 0.6 mm +0.14 mm 0.3 mm 3 0.5 mm 1 1.4 mm 0.5 mm +0.15 mm +0.16 mm +0.17 mm +0.18 mm +0.19 mm +0.20 mm 0.3 mm 0.3 mm 0.3 mm 0.3 mm 2 1 1 3 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 0.5 mm 3 2 3 3 2 4 1.5 mm 1.6 mm 1.8 mm 1.8 mm 1.9 mm 2.0 mm 0.5 mm 0.5 mm 0.6 mm 0.5 mm 0.5 mm 0.5 mm See Fig. 6

50-390

+c23

*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

q

50-391
3. Run the engine at low idle, and set cutting edge (1) of the bucket horizontal. Tilt the bucket approx. 35 degrees up (approx 10 degrees before the tilt back stroke end), return it to horizontal, tilt it approx. 35 degrees down (approx 10 degrees before the dump stroke end), and return it to horizontal. Repeat this cycle five times.

When disassemble or assemble the work equipment, or removing or installing it, perform running-in operation of the bucket pin and lift arm pin. a For running-in operation of lift arm pin, see "Procedure for running in lift arm pin". a Air must be bled from each cylinder before installing the work equipment assembly.

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 horizontal. 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 approx. 10 degrees up, return it to horizontal, tilt it approx. 10 degrees down, and return it to horizontal. Repeat this cycle five times.

5. Run the engine at 1500 rpm, 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 horizontal. Repeat this cycle five times.

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 edge (1) of the bucket horizontal. Tilt the bucket approx. 20 degrees up, return it to horizontal, tilt it approx. 30 degrees down, and return it to horizontal. Repeat this cycle five times. 9. Run the engine at full speed, and set cutting edge (1) of the bucket horizontal. Tilt the bucket approx. 35 degrees up (approx 10 degrees before the tilt back stroke end), return it to horizontal, 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 take proper actions. a Oil used for lubricated pin q Quality: API.GL-5 q Viscosity: SAE80W-90 q Operating temperature range: -30 C to +50 C q Total oil capacity: 86 l

7. cutting edge (1) of the bucket horizontal. Tilt the bucket approx. 35 degrees up (approx 10 degrees before the tilt back stroke end), return it to horizontal, tilt it approx. 35 degrees down (approx 10 degrees before the dump stroke end), and return it to horizontal. Repeat this cycle five times.

50-392

WA1200-6

Work equipment Procedure for running in lift arm pin

Procedure for running in lift arm pin

q

50-393
3. Run the engine at low idle, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position where lift arm cylinder (5) is approx. 100 mm before its stroke end. a A position where the lift arm is approx. 40 degrees up from the horizontal.

When disassemble or assemble the work equipment, or removing or installing it, perform running-in operation of the lift arm pin and bucket pin. a For running-in operation of bucket pin, see "Procedure for running in bucket pin". a Air must be bled from each cylinder before installing the work equipment assembly.

1. Run the engine at low idle, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position 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.

4. Run the engine at low idle, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position where lift arm cylinder(5) is at its stroke end (lift arm stroke end). a A position where the lift arm is approx. 46 degrees up from the horizontal. 2. Run the engine at low idle, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position 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 minimum 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 Procedure for running in lift arm pin

7. Run the engine at 1500 rpm, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position where lift arm cylinder (5) is approx. 100 mm before its stroke end. a A position where the lift arm is approx. 40 degrees up from the horizontal.

5. Run the engine at 1500 rpm, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position 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. 8. Run the engine at 1500 rpm, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position 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. a A position where the lift arm is approx. 40 degrees up from the horizontal

6. Run the engine at 1500 rpm, and move the work equipment up and down five times from a position where bucket (1) is on the ground to a position 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 minimum 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 Procedure for running in lift arm pin

9. Run the engine at full speed, and move the work equipment up and down five times from a position where bucket(1) is on the ground to a position 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

Removal and installation of bulkhead assembly

Removal 50-396 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice". 1. Remove the hood assembly, referring to "Removal and installation of hood assembly". 2. Remove the right handrail. 3. Remove all of partition covers (1).

50-396

50-396

4. Disconnect harness connectors B06 (2), B07 (3), B08 (4) and B09 (5), and disconnect wiring harness (6).

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). 7. Loosen hose clamps and remove tubes (13) and (14). 8. Loosen hose clamps and remove tubes (15) and (16). [*1] 9. Disconnect the battery cable bracket. 10. Disconnect hose, tube, and wiring harness connectors (ETH1 and ETH39) for the ether start aid cartridge. 11. Loosen hose clamps and remove hoses (17) 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

50-397 Installation Perform installation in the reverse order to the removal. When partition covers are removed, be sure to replace consumable parts as they are important as fire prevention covers. Hose clamp: 8.8 0.5 Nm {0.9 0.05 kgm}

[*1]

[*2]

Bulkhead mounting bolt: 157 to 196 Nm {16 to 20 kgm}

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

Removal
k

50-398

50-398

9. Remove covers (3) and (4). 10. Remove condenser top cover (5).

Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work", and "8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit" in "00 Safety notice". Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit.

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). 4. Remove the seven mounting bolts, and then remove cover (2a). 5. Sling cover (2b), remove five mounting bolts, and then remove the cover. 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.

11. Disconnect antenna wiring harness connector C25. 12. Sling ROPS (6), remove mounting bolts, and then remove the ROPS. [*1] 4 ROPS: 3,240 kg

8. Remove the wiring clamps and hose clamps, and then lift and remove the frame.

50-398

WA1200-6

Cab Removal and installation of operator's cab and floor assembly

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 Removal and installation of operator's cab and floor assembly

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, make sure that all the piping and wiring harnesses are disconnected. 4 Operator's cab and floor assembly: 540 kg

22. Disconnect washer hoses (30).

50-400

WA1200-6

Cab Removal and installation of operator's cab and floor assembly

Installation
q

50-401

perform installation in the reverse order to the removal.

[*1]

ROPS mounting bolt: 5,000 10% Nm {510 10% kgm} O-ring (on flange connection): Apply compressor oil (ND-OIL8) for the new type refrigerant. Precautions for charging air conditioner with refrigerant Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a). Keep the room temperature at 3 C or higher. (the system will not operate at temperatures below 3 C.) Use R134a refrigerant. Before charging the system with refrigerant, evacuate the system thoroughly by repeatedly applying vacuum to the system. (Vacuum must reach at least 100 kPa {-750 mmHg}.) Rough standard for the refrigerant refill capacity is 1.3 to 1.5 kg. 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. Do not let the compressor operate before refilling refrigerant. Operator's cab and floor mounting bolt nut: 245 to 309 Nm {25.0 to 31.5 kgm}

[*2]

q k

1) 2) 3)

4) 5)

6) [*3]

WA1200-6

50-401

Cab Removal and installation of operator's cab assembly

Removal and installation of operator's cab assembly

Removal
k

50-402

50-402

Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice".

4. Disconnect wiring harness connectors CL2(21), CL3(22), M01A(23), CL1(24), FCL1(25), and 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 Removal and installation of operator's cab assembly

5. Disconnect wiring harness connectors FC18(27), FC19(28), and FC20(29).

Installation
q

50-403

perform installation in the reverse order to the removal. 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 operator's cab assembly. a When removing the operator's cab assembly, make sure that all the piping and wiring harnesses are disconnected. 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

Removal 50-404 k Before performing removal, be sure to implement "2. Preparatory work", "3. Precautions during work", and "8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit" in "00 Safety notice". k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit. 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 operator's cab assembly". 3. Remove the mounting bolts, and then lift and remove operator's seat assembly (1). 4 Operator's seat assembly: 55 kg 4. Remove case (2). 5. Remove covers (3), (4), (5), and (6). 6. Remove console box (7).

50-404

7. Disconnect wiring harness connectors CL2(8) and CL3(9). 8. Disconnect wiring harness clamps (10) and (11).

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Cab Removal and installation of air conditioner unit assembly

9. Disconnect heater hoses (17) and (18). 10. Disconnect air conditioner hoses (19) and (20). [*1] 11. Remove the mounting bolts for air conditioner unit assembly (21), and then lift and remove the air conditioner unit assembly. 4 Air conditioner unit assembly: 55 kg

Installation
q

50-405

perform installation in the reverse order to the removal.

[*1]

O-ring (on flange connection): Apply compressor oil (ND-OIL8) for the new refrigerant. Precautions for charging air conditioner with refrigerant Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a). Keep the room temperature at 3 C or higher. (Because the system does not operate at temperatures below 3 C.) Use R134a refrigerant. 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}.) Rough charging amount of the refrigerant refill capacity is 1.3 to 1.5 kg. Be careful not to make mistakes, such as turning the refrigerant can upside down, as this may cause liquid Freon entering the refrigeration system. Do not let the compressor operate before refilling refrigerant.

q k

1) 2) 3)

4) 5)

6)

WA1200-6

50-405

Cab Disassembly and assembly of operator seat

Disassembly and assembly of operator seat

[Manufactured by GRAMMER] a The operator seat is not equipped with right and left armrests. The disassembling and assembling procedures for any components other than the armrests are the same. 50-406 I. Upper seat 1. Removal and installation of document box

50-406

2. Removal and installation of seat cushion and backrest cushion

Removal 1) Open document box (1). 2) Remove hook (3). 3) Remove screws (2) and remove document box (1). Installation 1) Install document box (1) and secure it with mounting screws (2). 2) Install hook (3).

Removal 1) Remove the document box. For details, see "1. Removal and installation of document box". 2) Remove four screws (1) and remove backrest cushion (2). 3) Remove five screws (4) and remove seat cushion (5). 4) Disconnect connectors (3) and (6). Installation 1) Connect connectors (3) and (6). 2) Install seat cushion (5) with five mounting screws (4). 3) Install backrest cushion (2) with four mounting screws (1). 4) Install the document box. For details, see "1. Removal and installation of document box".

50-406

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Cab Disassembly and assembly of operator seat

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 "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) Hollow the head of rivet (1) using a drill and remove spring plate (2) from lever (3). 4) Remove lever (3) from catch element (4). 5) Remove bolt (5) and remove knob (6) and gear (7). 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". 6) Install the document box. For details, see "1. Removal and installation of document box".

Removal 1) Remove cover (1). 2) Remove nut (2) and washer (3). 3) Remove armrest (4). Installation 1) Set armrests (4). 2) Install washer (3) and secure it with nut (2). 3 Mounting nut: 25 Nm {2.6 kgm} 3) Install cover (1).

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50-407

Cab Disassembly and assembly of operator seat

5. Removal and installation of backrest

Removal 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) Disassemble the recliner. For details, see "6. Disassembly and assembly of recliner". 4) Disassemble the recliner. For details, see "6. Disassembly and assembly of recliner". 5) Remove nut (5) and washers (6) and (7). 6) Remove bolt (11) and washer (10). 7) While gently pushing backrest (1) to the left, remove it upward. 8) Remove bearing (8) and spring (9) from backrest (1).

Installation 1) Install bearing (8) and spring (9) to backrest (1). a Apply non-acidic multi-purpose grease to the surface where (Q) of backrest (1) come into contact with bearing (8). a Put bearing (B/8) into back support (B/4). 2) While gently pushing backrest (1) to the left, install it upward. a Move the recliner until cylindrical protruding portion (C/2) fits into the positioning hole in backrest support (C/3) on the left side. a Engage spring (A/9) on the stopper welded to the backrest (A/1). 3) Install washer (10) and bolt (11). 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) 7) Install the backrest cushion. For details, see "2. Removal and installation of seat cushion and backrest cushion". 8) Install the document box. For details, see "1. Removal and installation of document box". WA1200-6

50-408

Cab Disassembly and assembly of operator seat

6. Disassembly and assembly of recliner

Disassembly 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. Removal and installation of armrests". (For a machine equipped with armrests) 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).

Assembly 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. Removal and installation of armrests". (For a machine equipped with armrests) 5) Install the backrest cushion. For details, see "2. Removal and installation of seat cushion and backrest cushion". 6) Install the document box. For details, see "1. Removal and installation of document box".

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Cab Disassembly and assembly of operator seat

7. Disassembly and assembly of seat angle and height adjustment levers

4)

5) Disassembly 1) Remove the seat cushion. For details, see "2. Removal and installation of seat cushion and backrest cushion". 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 to the following procedure. 1] While pushing (P) of spring seat (5) inward (in the direction of an arrow), pull up angle adjustment lever (6). 6) 7) 8)

2] Detach flexible support plate (7) from the lock and lift it toward the back to remove it. 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. Remove the right and left covers. For details, see "8. Removal and installation of cover". Remove nut (16), lever (14) and screw (17). Cut off rivet (18) and remove spring sheet (19). Cut off rivet (20) and remove notch plate (21).

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Cab Disassembly and assembly of operator seat

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 following procedure. 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).

3] Secure lock lever (12), link rod (11), levers (10) and (6), and cover (9) with mounting screws (8). 4] Install spring plate (5) and secure it with rivet (22). 6) Install flexible support plate (7) according to the following procedure. 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).

7) Install switch (4) according to the following procedure. (Only for a machine with a seat switch) 1] Install switch (4) and secure it with rivet (3). 2] Tilt switch plate (2) forward and install it. 3] Install springs (1). 8) Install the seat cushion. For details, see "2. Removal and installation of seat cushion and backrest cushion".

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Cab Disassembly and assembly of operator seat

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 adjustment levers".) 5) Install flexible support plate (4) according to the following procedure. (See "7. Disassembly 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. Removal and installation of seat cushion and 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 to the following procedure. 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 adjustment 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.

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Cab Disassembly and assembly of operator seat

9. Removal and installation of seat plate and slide rail

Installation 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). a Replace the bolts with new ones. 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). a Replace the bolts with new ones. 3 Mounting bolt: 25 Nm {2.6 kgm} 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. Removal and installation of seat cushion and 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 Disassembly and assembly of operator seat

II Suspension 1. Removal and installation of upper cover

50-414 2. Removal and installation of front cover

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Pull out power cable (3) from upper cover (2). 3) Remove pin (1), then remove upper cover (2). Installation 1) Run power cable (3) through the hole in upper cover (2). 2) Install upper cover (2) and secure it with mounting pin (1). 3) Install the upper seat. For details, see "I Upper seat".

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Hollow out the head of rivet (1) and remove cover (2). Installation 1) Install front cover (2) and secure it with rivet (1). 2) Install the upper cover. For details, see "1. Removal and installation of upper cover". 3) Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

3. Removal and installation of boot

5) Remove boot (5) from wire frame (2).

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove boot (2) from suspension upper part (1) according to the following procedure. 1] Remove six pins (4) from the front of the suspension upper part. 2] Remove pin (3) from the left side of the suspension upper part. 3] Remove two pins (4) and two pins (3) from the back of the suspension upper part. 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 suspension lower part.

Installation 1) Install wire frame (5) to boot (2). 2) Install boot (2). 3) Install the boot to suspension lower part (6) in the reverse order to removal. 4) Secure the connector cable with cable ties (10). (For a machine equipped with a connector cable) 5) Install the boot to suspension upper part (1) in the reverse order to removal. 6) Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

4. Removal and installation of damper adjustment wire and lever

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught and secure it to prevent it from lowering by inserting 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).

10)Mark the locations where pull wire (5) is secured by cable ties (8) before removing cable ties (8). 11)Remove fixing cap (12) from damper (13). 12)Remove pull wire (5) from bearing (9). 13)Disassemble fixing cap (12) and fork (11). 14)Remove pull wire (5) from fork (11) and remove fork (11) and spring (10). 15)Mark the location of the hole in upper part (4) through which pull wire (5) is fed before removing the entire wire.

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Cab Disassembly and assembly of operator seat

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 mechanism 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".

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50-417

Cab Disassembly and assembly of operator seat

5. Removal and installation of damper

Installation 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 mechanism 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). a Apply non-acidic multi-purpose grease to the entire surface (F) of stud (6). 7) Install circlip (8) to stud (6). 8) Install the boot. For details, see "3. Removal and installation of boot". 9) Install the upper cover. For details, see "1. Removal and installation of upper cover". 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. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught and secure it to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower 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).

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Cab Disassembly and assembly of operator seat

6. Removal and installation of compressor

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught and secure it to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower 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 removing the cable ties. 10)Pull out fitting (8) until it is removed from the discharge port of compressor (3), and pull out air hose (7). WA1200-6

11)Remove compressor air hose (7) from compressor (3). a Avoid using a screwdriver or similar tool that may damage the hose when removing it from the compressor. a Heating the end of hose by a hot air heater will ease the removal. 12)Pull compressor (3) forward while pulling compressor cable (5) downward. 13)Remove support (9) from suspension upper part (2).

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Cab Disassembly and assembly of operator seat

Installation 1) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught and secure it to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower 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. 12)Install the boot. For details, see "3. Removal and installation of boot". 13)Install the upper cover. For details, see "1. Removal and installation of upper cover". Install the rails. 14)Install the seat cushion. For details, see "2. Seat and backrest cushions" in "I Removal and installation of upper seat".

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Cab Disassembly and assembly of operator seat

7. Removal and installation of level controller

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught and secure it to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 5) Remove two circlips (17) from stud (18). 6) Remove stud (18) from lower part (15). a Carefully roll up belt (5) into the winder of level controller (1) while holding the belt tightly. 7) Remove two buffers (16) from belt (5). 8) Mark the locations where air hoses (10) and (11) are secured by cable ties (12) before 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.

11)Mark the locations where pull wire (19) is secured by cable ties before removing them. 12)Remove pull wires (3) and (19) from level controller (1). 13)Remove angle plugs (13) and (14) from level controller (1). a Mark the locations where angle plugs (13) and (14) are installed before removing them. 14)Remove two nuts (4) from the stud bolt on level controller (1). 15)Remove plate (7), belt (5), and edge protector (6). 16)Remove level controller (1) from suspension upper part (8). 17)Remove TORX screw (9) and remove wire attachment (2) from level controller (1). a Remove the attachment by pushing two catches (tabs) on the back of the attachment. 18)Remove pull wire (3) from attachment (2). 19)Remove the entire level controller.

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Cab Disassembly and assembly of operator seat

Installation 1) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between 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). 18)Install the boot. For details, see "1. Removal and installation of boot". 19)Install the upper cover. For details, see "1. Removal and installation of upper cover". 20)Install the seat cushion. For details, see "2. Seat and backrest cushions" in "I Disassembly and assembly of upper seat".

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Cab Disassembly and assembly of operator seat

Adjustment 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught and secure it to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 5) Loosen tapping screw (9) a half turn. 6) Adjust micro switch (3) according to the following procedure. Adjust the clearance between cam switch (5) and cam disc (7) by turning micro switch adjustment screw (8). q Specified clearance (A): 0.5 mm q Turning adjustment screw (8) to the left will move cam switch (5) closer to cam disc (7). q Turning adjustment screw (8) to the right will move cam switch (5) away from cam disc (7). 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 suspension. WA1200-6

7) Make adjustment of exhaust valve (2) according to the following procedure. Adjust the clearance between valve lever (6) and cam disc (7) by turning exhaust valve adjustment screw (10). q Specified clearance: Adjust valve lever (6) so that it slightly comes into contact with cam disc (7). q Turning adjustment screw (10) to the left will move valve lever (6) closer to cam disc (7). This will increase pressure on valve tappet (4), the exhaust timing being accelerated. q Turning adjustment screw (10) to the right will move valve lever (6) away from cam disc (7). This will decrease pressure on valve tappet (4), the exhaust timing being decelerated. 8) After finishing adjustment, retighten tapping screw (9). 9) Install the boot. For details, see "3. Removal and installation of boot". 10)Install the upper cover. For details, see "1. Removal and installation of upper cover". 11)Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

8. Installation and removal of air hose

a Avoid reusing the hose. If it is reused, make sure it is free from damage. Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught and secure it to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 5) Mark the locations where air hose (11) is secured by cable ties (12) before removing cable ties (12). 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 removing 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).

a Be sure to push retainer ring (13) of the quick coupling all the way down when removing the hose. 9) Mark the locations where angled hose (8) is secured by cable ties (6), (7), and (12) before removing the cable ties. 10)Remove angled hose (8). 11)Mark the locations where air hoses (3) and (4) are secured by cable ties (2) and (6) before removing the cable ties. 12)Remove air hoses (3) and (4) from air spring (9). 13)Remove the controller with hoses (3) and (4) being connected. (See "7. Removal and installation of level controller".) q Leave hoses (3) and (4) connected to the level controller to prevent the loosening of the hose connection on the level controller side.

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Cab Disassembly and assembly of operator seat

Installation a Be sure to replace any damaged hose with a new one. It is possible to cut out damaged part (approximately 12 mm) of the hose with special tool (14) and reuse the hose only once. After the hose is cut out, move the blue marking as long as it is cut. 1) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 2) Install the controller with hoses (3) and (4) being connected. a If hoses (3) and (4) are damaged, replace with new ones. Cut an extra length of the hose. 3) Install air hoses (3) and (4) to air spring (9). 4) Secure air hoses (3) and (4) with cable ties (2) and (6). 5) Install angled hose (8) to air spring and reservoir. 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.

6) Secure angled hose (8) with cable ties (6), (7), and (12). a Do not put cable ties on the angle. 7) Install air hose (11) to compressor (5). (See "6. Removal and installation of compressor".) 8) Install air hose (11) to air spring (9). 9) Secure air hose (11) with cable ties (12). 10)Install the boot. For details, see "3. Removal and installation of boot". 11)Install the upper cover. For details, see "1. Removal and installation of upper cover". 12)Install the upper seat. For details, see "I Upper seat". Air leakage test a After disassembling and assembling the air hose, be sure to perform the air leakage test. q Place a weight of 60 kg on the hose and leave it alone for 24 hours. q There should be no sinkage of more than 15 mm. a After connecting the air hose, check that it is appropriately locked.

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Cab Disassembly and assembly of operator seat

9. Removal and installation of height adjustment wire and lever

10)Remove entire holder (4) of pull wire. 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, adjust it to the same length as the one removed. 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 securing it. 7) Secure pull wire (1) with two cable ties (3). a Use care not to kink the wire when securing it. 8) Install the boot. For details, see "3. Removal and installation of boot". 9) Install the upper cover. For details, see "1. Removal and installation of upper cover". 10)Install the upper seat. For details, see "I Upper seat".

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Mark the locations where pull wire (1) is secured by two cable ties (3) before removing the cable ties. 5) Mark the locations where pull wire (6) is secured by two cable ties (8) before removing the cable ties. 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 raising height adjustment lever (5). 7) Remove pull wire (6) from the level controller. (See "7. Removal and installation of level controller".) a Loosen the tension of pull wire (6) by raising 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).

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Cab Disassembly and assembly of operator seat

Testing and adjusting a Perform the following measurements and adjustments for height adjustment before installing the top cover. a To perform measurements and assembling during the course of disassembly and assembly, omit steps 1) and 2) in Measuring. (Measuring) 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Move height adjustment lever (2) up and down several times to check that: q Pull wires (1) and (3) move smoothly. q Pull wire (10), valve lever (14), and tappet (13) of the exhaust valve move smoothly. 4) Check the tension of spring (11) for the level control and valve with height adjustment lever (2) placed in the middle position. q Spring (11) secures the height adjustment 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

a The suspension will not rise when this value is over 3.5 mm. (Adjustment) 1) Adjusting pull wire (3) 1] The clearance between wire lever (10) and wire holder (9) can be adjusted by loosening counter nut (6) and turning lock nut (5). q Turn lock nut (5) inward to increase the length of wire. q Turn lock nut (5) outward to decrease the length of wire. Specified value: Clearance (A) is 1 to 3.5 mm (with the height adjustment lever raised) 2] After the adjustment, secure lock nut (5) with counter nut (6). Take care not to kink wire (3). 3] Check that the specified value is satisfied by moving the height adjustment lever up and down several times.

WA1200-6

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Cab Disassembly and assembly of operator seat

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 independently without performing disassembly and assembly, perform steps 10) to 12) and then install the seat cushion.

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Cab Disassembly and assembly of operator seat

10. Removal and installation of air spring

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Remove two hoses from air spring (6). (See "8. Installation and removal of air hose".) 5) Remove countersunk screw (3) and washer (4) from the air spring. 6) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 7) Turn the entire suspension upside down. 8) Remove countersunk screw (7) from the air spring. 9) Compress air spring (6) and remove swing arm (5) and lower part (2).

Installation 1) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 2) Turn the entire suspension upside down. 3) Compress air spring (6) and set it between swing arm (5) and lower part (2). a Move the air spring until protruding portion (6) on the bottom of the air spring fits into the hole in the suspension lower part. 4) Install countersunk screw (7) to the air spring. 3 Mounting screw: 6 Nm {0.61 kgm} 5) Turn the entire suspension back to its original position. 6) Fit washer (4) to countersunk screw (3) and install it to the air spring. 3 Mounting screw: 6 Nm {0.61 kgm} 7) Install two air hoses to air spring (6). (See "8. Installation and removal of air hose".) 8) Install the boot. For details, see "3. Removal and installation of boot". 9) Install the upper cover. For details, see "1. Removal and installation of upper cover".

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Cab Disassembly and assembly of operator seat

10)Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

11. Removal and installation of air reservoir

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 5) Remove angled hose (4) from air reservoir (3). (See "8. Installation and removal of air hose".) 6) Remove air reservoir (3) from bracket (2) and clamp (5). 7) Remove clamp (5) from bracket (6). (If replacement is required) 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.

Installation 1) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 2) Install clamp (5), if removed, to bracket (6). a Replace clamp (5) if necessary. 3) Install air reservoir (3) to bracket (2) and clamp (5). 4) Install angled hose (4) to air reservoir (3). (See "8. Installation and removal of air hose".) 5) Install the boot. For details, see "3. Removal and installation of boot". 6) Install the upper cover. For details, see "1. Removal and installation of upper cover". 7) Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

12. Removal and installation of harness

Removal 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 5) Mark the location where power cable (3) is secured by cable tie (8) before removing the cable tie. 6) Mark the location where connector cable (2) and vehicle power cable (3) are secured by cable ties (5) before removing the cable ties. 7) Disconnect flat plug, connector plug and harness (2) of compressor cable (4) from vehicle power cable (3). (See "8. Installation and removal of air hose".) 8) Remove angle plug (6) from the level controller.

Installation 1) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between the swing arm mechanism and the lower part. 2) Install angle plug (6) to level controller (1). 3) Install flat plug, connector plug and harness (2) of compressor cable (4) to vehicle power cable (3). (See "8. Installation and removal of air hose".) 4) Secure connector cable (2) and power cable (3) with cable ties (5). a Run harnesses (2) and (3) taking care not to allow them to get caught in other parts when securing them with cable ties. 5) Secure power cable (3) with cable ties (8). 6) Install the boot. For details, see "3. Removal and installation of boot". 7) Install the upper cover. For details, see "1. Removal and installation of upper cover". 8) Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

13. Disassembly and assembly of suspension upper part

Disassembly 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Remove the damper adjustment lever and pull wire from suspension upper part (1). (See "4. Removal and installation of damper adjustment wire and lever".) a It is not necessary to remove the wire from the damper. 5) Remove the damper from suspension upper part (1). (See "5. Removal and installation of 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".)

8) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between swing arm mechanism (7) and the lower part. 9) Hollow the head of two rivets (10) to remove them, and remove stopper (9). 10)Push suspension upper part (1) forward to move roller (8) to the opening (indicated by an arrow) in guide rail (2). 11)Raise upper part (1) and remove it from front roller (8) and rear roller (6) in swing arm mechanism (7).

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50-433

Cab Disassembly and assembly of operator seat

Assembly 1) Raise the suspension to the uppermost level. k Raise the suspension taking care not to get your hand caught. Secure the suspension to prevent it from lowering by inserting an appropriate spacer between 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 mechanism (7). a Apply non-acidic multi-purpose grease to 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). (See "7. Removal and installation of level 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 adjustment wire and lever".) 9) Install the boot. For details, see "3. Removal and installation of boot". 10)Install the upper cover. For details, see "1. Removal and installation of upper cover". 11)Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

14. Disassembly and assembly of suspension lower part

Disassembly 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 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

11)Raise upper part (1) and swing arm (3) to remove roller (2) from guide rail (8).

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Cab Disassembly and assembly of operator seat

Assembly 1) Raise upper part (1) and swing arm (3) to install roller (2) to guide rail (8). a Apply non-acidic multi-purpose grease to 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". 8) Install the boot. For details, see "3. Removal and installation of boot". 9) Install the upper cover. For details, see "1. Removal and installation of upper cover". 10)Install the upper seat. For details, see "I Upper seat".

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Cab Disassembly and assembly of operator seat

15. Disassembly and assembly of swing arm

Disassembly 1) Remove the upper seat. For details, see "I Upper seat". 2) Remove the upper cover. For details, see "1. Removal and installation of upper cover". 3) Remove the boot. For details, see "3. Removal and installation of boot". 4) Remove the pull wire from the damper. (See "4. Removal and installation of damper adjustment wire and lever".) 5) Remove the damper from the swing arm. (See "5. Removal and installation of damper".) 6) Remove the compressor. (See "6. Removal and installation of compressor".) 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

12)Remove the harness. (See "12. Removal and installation of harness".) 13)Remove the suspension upper part from the swing arm. (See "13. Disassembly and assembly of suspension upper part".) 14)Remove the suspension lower part from the swing arm. (See "14. Disassembly and assembly of suspension lower part".) 15)Remove four rollers (5), two rollers (6), two bearings (9) and four felt rings (4) from swing arm (1). 16)Remove tube (8) from bearing (9). 17)Remove buffer (7) from swing arm (1). 18)Remove edge protector (2) from swing arm (1).

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Cab Disassembly and assembly of operator seat

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. (See "7. Removal and installation of level 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 adjustment wire and lever".) 18)Install the boot. For details, see "3. Removal and installation of boot". 19)Install the upper cover. For details, see "1. Removal and installation of upper cover". 20)Install the upper seat. For details, see "I Upper seat".

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Electrical system Removal and installation of DT connector pin

Electrical system

Removal and installation of DT connector pin

Removal 50-439 1. Using nippers, tweezers, or pull-out tool, pull out wedge (1) from the DT connector. (The following photo shows the male side.)

50-439

50-439

50-439 Installation 1. Hold wire (4) 30 mm away from the rear of the caulked portion of the contact.

2. While disconnecting contact fixing claw (2) in the connector from the contact by using flat-head screwdriver, tweezers, or pull-out tool, pull out wires, and release the fixing claw.

2. Insert wire (4) in the grommet side of the connector. a Insert the contact for selecting wire (4) straight into the grommet insertion hole until 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 direction, 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.)

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Electrical system Removal and installation of HD connector pin

Removal and installation of HD connector pin

Removal 50-4 1 1. Select the appropriate tool for the wire size from the "special tools list", and install it to the wire of the pin to be removed.

50-4 1

50-4 1 Installation 1. Hold wire (2) 30 mm away from the rear of the caulked portion of the contact.

2. Insert tool X1 into the clearance of wire connector rubber shield (1), and press it against the contact. a Use a larger tool than the wire. a Take care not to damage the contact. 3. Pull out wire (2) together with tool X1.

2. Insert the wire in the grommet of the connector. a Insert the contact straight into the grommet insertion hole until 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 direction, 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

1. Remove the wire cover. a For removal dimensions, see the table below,
Wire size JIS SAE 0.5 224AWG 0.50.85 1620AWG 1.252.0 1416AWG 2.03.0 1214AWG 7.0 810AWG 15.0 6AWG Cover removal dimensions (mm) 3.965.54 6.357.92 6.357.92 5.647.21 10.912.5 10.912.5

50-4 2
5. Insert contact (5) into caulking tool X2. a Adjust adjustment screw (4) so that the upper side of contact (5) is level with the top edge "a" of the tool hole. Then, fasten lock nut (3).

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.

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Electrical system Removal and installation of controller assembly

Removal and installation of controller assembly

Removal 50-4 3 k Before performing removal, be sure to implement "2. Preparatory work" and "3. Precautions during work" in "00 Safety notice".
q q q

50-4 3

5. Disconnect wiring harness connectors L5, L6, and L7. Remove the mounting bolts and remove BBC controller assembly (6).

ATC controller assembly VHMS controller assembly BBC controller assembly

1. Remove covers (1) and (2).

Engine controller assembly

6. Disconnect wiring harness connectors (7), (8), and (9). Remove the mounting bolts and remove engine controller assembly (10).

2. Remove cover (3).

50-4 3 Installation perform installation in the reverse order to the removal.

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).

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50-443

Electrical system Removal and installation of controller assembly

50-444

WA1200-6

SEN0547529-00

60-1

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

6-01

Machine model
WA1200-6

Serial number
60001 and up

60 Maintenance standard

60-1

WA1200-6

60-1

Contents

Contents
60 Maintenance standard Engine and cooling system ..................................................................................................... Engine mount....................................................................................................................... Cooling system .................................................................................................................... Cooling fan motor................................................................................................................. Damper ................................................................................................................................ Power train.............................................................................................................................. Transmission mount............................................................................................................. Torque converter.................................................................................................................. Main relief valve, torque converter relief valve..................................................................... Torque converter regulator valve ......................................................................................... ECMV................................................................................................................................... Transmission........................................................................................................................ Transmission control valve .................................................................................................. Lubrication relief valve ......................................................................................................... Transfer................................................................................................................................ Torque converter pump, transmission pump, brake cooling pump, brake pump ................. Drive shaft............................................................................................................................ Center support ..................................................................................................................... Differential............................................................................................................................ Final drive ............................................................................................................................ Steering system ...................................................................................................................... Steering pump...................................................................................................................... Switch pump ........................................................................................................................ Steering demand valve ........................................................................................................ Diverter valve ....................................................................................................................... Steering cylinder mount ....................................................................................................... Steering cylinder .................................................................................................................. Emergency steering pump ................................................................................................... Brake system .......................................................................................................................... Brake valve .......................................................................................................................... Slack adjuster ...................................................................................................................... Brake.................................................................................................................................... Parking brake....................................................................................................................... Undercarriage and frame ........................................................................................................ axle mount ........................................................................................................................... Center hinge pin................................................................................................................... Hydraulic system..................................................................................................................... No.1 work equipment pump ................................................................................................. No.2 work equipment pump ................................................................................................. PPC relief valve ................................................................................................................... Pump control relief valve...................................................................................................... Work equipment control valve.............................................................................................. Work equipment...................................................................................................................... Work equipment linkage ...................................................................................................... Bucket positioner, remote positioner.................................................................................... Work equipment cylinder ..................................................................................................... Electrical system ..................................................................................................................... Work equipment control lever .............................................................................................. 6060606060606060606060606060606060606060606060606060606060606060606060606060606060606060606060603 3 4 5 7 8 8 10 14 16 17 18 20 23 24 26 28 30 32 36 38 38 39 41 43 44 45 47 48 48 50 51 52 54 54 56 59 59 62 65 66 67 69 69 74 75 77 77

60-2

60-2

WA1200-6

Engine and cooling system Engine mount

Engine and cooling system

Engine mount

60-3

60-3

WA1200-6

60-3

Engine and cooling system Cooling system

Cooling system

60-4

No.
Average wind speed

Item
Engine speed: 1,900 rpm

Unit
m/s % C C C

Criteria
15 or above 91 50 6.3 to 8 11 to 13

Remarks

Load factor Ambient temperature (conversion) 1 2

Radiator inlet/outlet water temperature difference Hydraulic oil cooler inlet/outlet oil temperature difference Torque converter oil cooler

See Inspection and Adjustment - "Radiator Performance Check". See Inspection and Adjustment - "Hydraulic Oil Cooler Performance Check (Check by Temperature Difference)". See Inspection and Adjustment - "Torque Converter Oil Cooler Performance Check".

3 inlet/outlet oil temperature difference

C C

11 to 13 104.5

Hydraulic tank oil temperature

60-4

WA1200-6

Engine and cooling system Cooling fan motor

Cooling fan motor

Model: LMF40 60-5

60-5

WA1200-6

60-5

Engine and cooling system Cooling fan motor

Unit: mm

No.

Item

Criteria
Standard dimension Free length x Load at Installed Outside diaminstalled length eter length 931 N 33.5 x 31 25.5 {95 kg} 3.43 N 13.0 x 6.5 7 {0.35 kg} 68 N 12.2 x 7.9 10 {6.9 kg} Repair limit Load at Free installed length length 745 N 32.7 {76 kg} 2.74 N 12.7 {0.28 kg} 54.4 N 11.9 {5.52 kg}

Remedy

1 Center spring

If damaged or deformed, replace spring

2 Check valve spring 3 Spring return spring

60-6

WA1200-6

Engine and cooling system Damper

Damper

60-7

Unit: mm

No. 1 2 3 4 5 6

Item
Clearance between bearing and shaft Clearance between bearing and housing Clearance between spacer and shaft Wear of oil seal contact surface of shaft Wear of spacer oil seal contacting surface Wear of spacer O-ring contacting surface Standard dimension

Criteria
Tolerance Shaft Hole +0.018 0 120 +0.003 -0.020 0 -0.008 215 -0.030 -0.037 +0.018 -0.020 120 +0.003 -0.042 Standard dimension Tolerance 0 150 -0.100 0 140 -0.100 0 140 -0.100 0.091 to 0.261 Standard clearance Allowable clearance

Remedy

-0.038 to 0 -0.003 -0.037 to 0.025 0.022 -0.060 to 0 -0.023 Repair limit -0.160 -0.160 -0.160

Replace

Repair chrome plating or replace

7 Backlash of spline

Replace

WA1200-6

60-7

Power train Transmission mount

Power train

Transmission mount

60-8

60-8

60-8

WA1200-6

Power train Transmission mount

Unit: mm

No. 1 2 3

Item
Clearance between torque converter case and trunnion Clearance between bracket and bushing Clearance between bushing and bracket Standard dimension 320 90 125

Criteria
Tolerance Standard Allowable clearance clearance Shaft Hole -0.125 +0.089 0.125 to -0.214 0 0.303 0 +0.035 0 to -0.035 0 0.070 +0.123 +0.089 -0.123 to +0.083 0 -0.006 Center of top and bottom center pins and transmission output shaft Parallelism of coupling contacting surface must be 0.15 mm or less.

Remedy

Replace

4 Standard shim thickness for mount

1.5 mm

WA1200-6

60-9

Power train Torque converter

Torque converter
(Input transfer, PTO, modulation clutch, torque converter) 60-10 Input transfer, PTO

60-10

60-10

WA1200-6

Power train Torque converter

Unit: mm

No. 1 seal 2 3 4 5 6

Item
Outside diameter of coupling oil contacting surface Backlash between drive gear and PTO gear Backlash between driver gear and idler gear Backlash between idler gear and driven gear Interference of drive gear and bearing Standard dimension f110

Criteria
Tolerance 0 -0.087 0.15 to 0.33 0.15 to 0.33 0.15 to 0.32 Standard dimension f100 f180 f100 f180 f100 f180 Tolerance Shaft Hole +0.045 0 +0.023 -0.20 0 -0.012 -0.025 -0.052 +0.045 0 +0.023 -0.20 0 -0.012 -0.025 -0.052 +0.045 0 +0.023 -0.20 0 -0.012 -0.025 -0.052 Standard clearance 0.023 to 0.065 -0.023 to 0.052 0.023 to 0.065 -0.023 to 0.052 0.023 to 0.065 -0.023 to 0.052 Allowable clearance 0.023 to 0.065 -0.023 to 0.052 0.023 to 0.065 -0.023 to 0.052 0.023 to 0.065 -0.023 to 0.052 Repair limit 109.8

Remedy
Repair by hard chrome plating or replace

Interference of drive gear bearing and cage Interference of PTO gear and bear7 ing Interference of PTO gear bearing 8 and cage Interference of idler gear and bear9 ing Interference of idler gear bearing 10 and cage

Replace

WA1200-6

60-11

Power train Torque converter

Modulation clutch

60-12

Unit: mm

No. 1

Item
Bore of bush seal ring contacting surface Wear of seal ring of
Width Thickness

Criteria
Standard dimension f85 3 3.5 107.6 3.2 2.6 Tolerance +0.035 0 -0.01 -0.03 0.1 0.41 0.08 0.05 Repair limit 84.8 2.7 3.35 96.2 2.6 2.34

Remedy

2 modulation clutch output

shaft Total thickness of assembly of 19 disks and 18 plates for modulation clutch Modulation clutch disk thickness Modulation clutch plate thickness

Replace

3 4 5

60-12

WA1200-6

Power train Torque converter

Torque converter

60-13

Unit: mm

No. 1 2 3

Item
Bore of retainer seal ring contacting surface Bore of sleeve seal ring contacting surface Wear of retainer seal ring
Width Thickness

Criteria
Standard dimension f180 f85 5.95 6.3 9 32 Tolerance +0.040 0 +0.035 0 0 -0.1 0.1 0.1 0.1 Repair limit 180.5 85.1 5.45 5.67

Remedy
Repair by hard chrome plating or replace

Replace

4 Plate thickness 5 Retainer thickness

8.5 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

No. 1 2 3 4

Item
Clearance between main relief valve spool and valve body Clearance between main relief valve spool and piston Clearance between torque converter relief valve spool and valve body Clearance between torque converter relief valve spool and piston Main relief valve valve spring (outer) Main relief valve valve spring (inner) Main relief valve piston spring Torque converter relief valve valve spring Torque converter relief valve piston spring Standard dimension f50 f32 f40 f28

Criteria
Tolerance Shaft Hole -0.035 +0.016 -0.045 0 -0.020 +0.025 -0.030 0 -0.035 -0.045 +0.016 0 Standard clearance 0.035 to 0.061 0.020 to 0.055 0.035 to 0.061 Allowable clearance 0.081 0.075 0.081

Remedy

6 7 8 9

-0.020 +0.021 -0.030 0 Standard dimension Installation Installation Free length length load 958 N 143.2 105 {97.8 kg} 1,102 N 130.6 105 {112.4 kg} 30.0 N 53 33 {3.06 kg} 677.6 N 116.92 84.8 {69.1 kg} 30.0 N 53 33 {3.06 kg}

0.020 to 0.071 0.051 Repair limit Installation Free length load 910.1 N 138.9 {92.9 kg} 1,046.9 N 126.7 {106.8 kg} 28.5 N 51.4 {2.91 kg} 644.3 N 113.4 {65.7 kg} 28.5 N 51.4 {2.91 kg}

Replace

WA1200-6

60-15

Power train Torque converter regulator valve

Torque converter regulator valve

60-16

Unit: mm

No. 1

Item
Clearance between torque converter regulator valve spool and valve body Clearance between torque conStandard dimension f40 f22 Shaft -0.035 -0.045 -0.020 -0.030

Criteria
Tolerance Hole +0.016 0 +0.021 0 Standard clearance 0.035 to 0.061 0.020 to 0.051 Allowable clearance 0.081 0.071

Remedy

2 verter regulator valve spool and piston Torque converter regulator valve valve spring (outer) Torque converter regulator valve valve spring (inner) Torque converter regulator valve piston spring

4 5

Standard dimension Installation Installation Free length length load 165.2 N 160.4 93 {16.85 kg} 72.3 N 160 93 {7.37 kg} 27.9 N 38.2 21 {2.84 kg}

Repair limit Installation Free length load 156.9 N 155.6 {16.01 kg} 68.7 N 155.2 {7.0 kg} 26.5 N 37.1 {2.7 kg}

Replace

60-16

WA1200-6

Power train ECMV

ECMV
(For modulation clutch)

60-17
60-17

Unit: mm

No. 1 2 3

Item
Clearance between flow rate detection valve spool and valve body Standard dimension

Criteria
Tolerance Standard clearance Allowable clearance

Remedy

5 6

Shaft Hole -0.035 +0.013 f19 -0.045 0 Clearance between pressure -0.035 +0.011 f14 control valve spool and valve body -0.045 0 Clearance between pressure -0.035 +0.012 f5.7 control valve spool and piston body -0.045 0 Standard dimension Installation Installation Free length Spring for fill switch length load 41.7 N 15 13 {4.25 kg} Flow rate detection valve 4.9 N 33.5 29.5 return spring {0.5 kg} Pressure control valve 10.6 N 16.2 11.7 return spring {1.08 kg}

0.035 to 0.064 0.058 0.035 to 0.062 0.056 0.035 to 0.063 0.057 Repair limit Installation Free length load 37.6 N 14.7 {3.83 kg} 4.4 N 32.8 {0.45 kg} 9.5 N 15.9 {0.97 kg}

Replace

WA1200-6

60-17

Power train Transmission

Transmission

60-18

60-18

WA1200-6

Power train Transmission

Unit: mm

No.

Item

Criteria
Standard dimension Installation Installation Free length length load 379.5N 133 94 {38.7kg} 536.4N 168 106 {54.7kg} 357.9N 68.8 55 {36.5kg} 42.7N 56.9 43 {43.0kg} 1697N 9.5 8.8 {173.0kg} Standard dimension Tolerance 83.8 95.0 50.2 39.0 77.6 5.4 4.8 5.8 4.3 3 3.5 4 4.6 6 6.8 0.39 0.41 0.30 0.26 0.41 0.1 0.1 0.1 0.1 -0.01 -0.03 0.1 -0.01 -0.03 0.12 -0.01 -0.03 0.15 0.16 to 0.40 0.18 to 0.43 0.19 to 0.47 0.17 to 0.39 0.18 to 0.44 0.35 to 0.80 (both sides) Allowable clearance Installation Free length load 322.6N 125.02 {32.9kg} 456.0N 157.92 {46.5kg} 304.0N 64.67 {31.0kg} 358.9N 53.49 {36.6kg} 1443N 8.93 {147.1kg} Repair limit 79.5 90.2 47.5 36.9 72.8 4.87 4.27 5.22 3.87 2.7 3.35 3.6 4.45 5.5 6.65

Remedy

1 No.1 clutch spring (x 6)

2 No.2 clutch spring (x 6) 3 No.3 clutch spring (x 6) 4 No.4 clutch spring (x 6) 5 No.5 clutch spring (x 3) 6 7
Total thickness of assembly of 8 disks and 7 plates for No.1 clutch

Total thickness of assembly of 9 disks and 8 plates for No.2 clutch Total thickness of assembly of 5 8 disks and 4 plates for No.3 clutch Total thickness of assembly of 4 9 disks and 3 plates for No.4 clutch Total thickness of assembly of 9 10 disks and 8 plates for No.5 clutch

11 Thickness of No.1 to 4 clutch disks 12 Thickness of No.5 clutch disk 13 Thickness of No.1 to 4 clutch plates 14 Thickness of No.5 clutch plate
Wear of transmission 15 input shaft sealing
Width Thickness Width Thickness Width Thickness

Replace

Wear of transmission 16 output shaft sealing

Wear of No.5 clutch 17 sealing

18 19 20 21 22

Backlash between No.1, 2, 3 sun gears and planet pinion Backlash between No.1 planet pinion and ring gear internal tooth Backlash between No.2 and 3 planet pinions and ring gear internal tooth Backlash between No.4 sun gear and planet pinion Backlash between No.4 planet pinion and ring gear internal tooth

23 Side clearance of planet pinion

WA1200-6

60-19

Power train Transmission control valve

Transmission control valve

ECMV (for transmission) 60-20

60-20

Unit: mm

No. 1 2 3

Item
Clearance between flow rate detection valve spool and valve body Clearance between pressure control valve spool and valve body Clearance between pressure control valve spool and piston Standard dimension

Criteria
Tolerance Shaft Hole -0.035 +0.013 f19 -0.045 0 -0.035 +0.011 f14 -0.045 0 -0.035 +0.012 f5.7 -0.045 0 Standard dimension Installation Installation Free length length load 41.7 N 15 13 {4.25 kg} 4.9 N 33.5 29.5 {0.5 kg} 10.6 N 16.2 11.7 {1.08 kg} Standard clearance Allowable clearance

Remedy

4 Spring for fill switch

Flow rate detection valve return spring Pressure control valve return spring

5 6

0.035 to 0.064 0.058 0.035 to 0.062 0.056 0.035 to 0.063 0.057 Repair limit Installation Free length load 37.6 N 14.7 {3.83 kg} 4.4 N 32.8 {0.45 kg} 9.5 N 15.9 {0.97 kg}

Replace

60-20

WA1200-6

Power train Transmission control valve

Clutch bypass fill valve (For forward clutch and 1st clutch)

60-21

Unit: mm

No. 1

Item
Clearance between bypass fill valve spool and valve body Standard dimension

Criteria
Tolerance Shaft Hole -0.035 +0.011 f14 -0.045 0 Standard dimension Installation Installation Free length length load 63.7 N 33.4 17.3 {6.5 kg} 33.3 N 38.2 17.3 {3.4 kg} Standard clearance Allowable clearance

Remedy

Bypass fill valve return spring (outer) Bypass fill valve return spring (inner)

0.035 to 0.076 0.056 Repair limit Installation Free length load 60.8 N 32.4 {6.2 kg} 31.4 N 37.1 {3.2 kg}

Replace

WA1200-6

60-21

Power train Transmission control valve

Clutch bypass fill valve, bypass drain valve (for reverse clutch)

60-2

Unit: mm

No. 1 2

Item
Clearance between bypass fill valve spool and valve body Clearance between bypass drain valve spool and valve body Bypass fill valve return spring (outer) Bypass fill valve return spring (inner) Bypass drain valve return spring Standard dimension

Criteria
Tolerance Shaft Hole -0.035 +0.011 f14 -0.045 0 -0.035 +0.011 f14 -0.045 0 Standard dimension Installation Installation Free length length load 63.7 N 33.4 17.3 {6.5 kg} 33.3 N 38.2 17.3 {3.4 kg} 63.7 N 33.4 17.3 {6.5 kg} Standard clearance Allowable clearance

Remedy

4 5

0.035 to 0.076 0.056 0.035 to 0.076 0.056 Repair limit Installation Free length load 60.8 N 32.4 {6.2 kg} 31.4 N 37.1 {3.2 kg} 60.8 N 32.4 {6.2 kg}

Replace

60-22

WA1200-6

Power train Lubrication relief valve

Lubrication relief valve

60-23

Unit: mm

No. 1

Item
Clearance between lubrication relief valve spool and valve body Standard dimension

Criteria
Tolerance Shaft Hole -0.035 +0.013 f22 -0.045 0 Standard dimension Installation Installation Free length length load 91.9 N 68.5 37 {9.37 kg} Standard clearance Allowable clearance

Remedy

Lubrication relief valve valve spring

0.035 to 0.078 0.058 Repair limit Installation Free length load 87.3 N 66.4 {8.9 kg}

Replace

WA1200-6

60-23

Power train Transfer

Transfer

60-24

60-24

WA1200-6

Power train Transfer

Unit: mm

No. 1 2 3 4 5 6

Item
Outside diameter of front coupling oil seal contacting surface Outside diameter of rear coupling oil seal contacting surface Backlash between input gear and idler gear Backlash between idler gear and output gear Interference of input gear and bearing Standard dimension f140 f140

Criteria
Tolerance +0.052 +0.027 +0.052 +0.027 0.25 to 0.65 0.25 to 0.65 Standard dimension f140 f250 f140 f250 f120 f215 f169 f250 Tolerance Shaft Hole +0.078 0 +0.060 -0.025 0 -0.014 -0.030 -0.060 +0.078 0 +0.060 -0.025 0 -0.014 -0.030 -0.060 +0.045 0 +0.023 -0.020 0 -0.014 -0.030 -0.060 0 +0.025 -0.02 0 0 -0.014 -0.030 -0.060 Standard Allowable interference interference 0.060 to 0.103 -0.016 to 0.060 0.060 to 0.103 -0.016 to 0.060 0.023 to 0.065 -0.016 to 0.060 -0.045 to 0 -0.016 to 0.060 0.060 to 0.103 -0.016 to 0.060 0.060 to 0.103 -0.016 to 0.060 0.023 to 0.065 -0.016 to 0.060 -0.045 to 0 -0.016 to 0.060 Repair limit 139.8 139.8

Remedy

Interference of input gear bearing and transfer case Interference of idler gear and bear7 ing Interference of idler gear bearing 8 and transfer case Interference of output shaft and 9 bearing Interference of front output bearing 10 and transfer case

Replace

11 Interference of spacer and bearing 12

Interference of rear output bearing and parking brake cover

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) Model: SAR(4)200 + 200 + (3)71 + (2)40 60-26 60-26

60-26

WA1200-6

Power train Torque converter pump, transmission pump, brake cooling pump, brake pump

Unit: mm

No.

Item
Type SAR (4) 200

Criteria
Standard clearance 0.14 to 0.19 0.14 to 0.19 0.10 to 0.15 0.10 to 0.15 0.06 to 0.14 0.06 to 0.14 0.06 to 0.149 0.06 to 0.125 Standard dimension 14 13 13 Tolerance 0 -0.5 0 -0.5 0 -0.5 Allowable clearance 0.22 0.22 0.19 0.19 0.20 0.20 0.20 0.20 Repair limit

Remedy

1 Side clearance

SAR (4) 200 SAR (3) 71 SAR (2) 40 SAR (4) 200

Clearance between plain bearing

SAR (4) 200 SAR (3) 71 SAR (2) 40 Type SAR (4) 200

2 inside diameter and gear shaft outside diameter Replace

3 Pin driving depth

SAR (4) 200 SAR (3) 71 SAR (2) 40

4 Spline shaft rotating torque

Type

29.4 to 48.1 Nm {3.0 to 4.9 kgm} Revolutions (rpm) Delivery pressure MPa {kg/cm2} Standard delivery (r/min.) 389 2.9 {30} 2000 SAR (3) 71 SAR (2) 40 20.6 {210} 130 70 115 62 389 Allowable delivery (r/min.) 357 SAR (4) 200 357

Delivery

Oil: EO10-CD
Oil temperature: 45 to 55 C

SAR (4) 200

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

No. 1 2 3 4

Item
Clearance between case and bearing Clearance between case and bearing Clearance between coupling shaft and bearing Clearance between coupling shaft and bearing Standard dimension

Criteria
Tolerance Shaft Hole 0 -0.022 230 -0.030 -0.051 0 -0.022 215 -0.030 -0.051 +0.052 0 130 +0.027 -0.025 +0.045 0 120 +0.023 -0.020 Standard dimension Tolerance 0 160 -0.100 0 160 -0.100 Standard clearance Allowable clearance

Remedy

-0.051 to 0.011 0.008 -0.051 to 0.011 0.008 -0.077 to -0.024 -0.027 -0.065 to -0.020 -0.023 Repair limit -0.160 -0.160

Replace

5 Wear of oil seal contacting surface 6 Wear of oil seal contacting surface

Repair chrome plating or replace

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

No. 1 2

Item
Clearance of side bearing outer race of differential gear ass'y Standard dimension 280 180 273.05 120.65 374.65 161.925 160 90 140 90 540 70 Shaft 0 -0.018 +0.100 +0.075 +0.025 0 +0.025 +0.003 +0.051 0 +0.064 +0.038 0 -0.025 +0.013 -0.009 0 -0.018 +0.013 -0.009 0 -0.070 0 -0.030

Criteria
Tolerance Hole +0.015 -0.016 0 -0.025 -0.025 -0.076 +0.025 0 -0.025 -0.076 +0.025 0 -0.028 -0.068 0 -0.015 -0.028 -0.068 0 -0.015 +0.070 0 +0.030 0 0.43 to 0.61 0.31 to 0.40 7.8 to 35.3 N {800 to 3,600 kg} Standard clearance -0.016 to 0.032 -0.125 to -0.075 -0.101 to -0.025 -0.025 to 0.022 -0.127 to -0.025 -0.064 to -0.013 -0.068 to -0.003 -0.028 to 0.009 -0.068 to -0.010 -0.028 to 0.009 0 to 0.140 0 to 0.060 Allowable clearance

Remedy

Clearance of side bearing inner race of differential gear ass'y Clearance of outer race of pinion 3 shaft bearing Clearance of inner race of pinion 4 shaft bearing Clearance of outer race of pinion 5 shaft bearing Clearance of inner race of pinion 6 shaft bearing Clearance of outer race of differen7 tial pinion gear bearing Clearance of inner race of differen8 tial pinion gear bearing Clearance of outer race of differen9 tial pinion gear bearing Clearance of inner race of differen10 tial pinion gear bearing Clearance between differential car11 rier and cage Clearance between spider and dif12 ferential pinion

Replace

13 Backlash of bevel gear 14 Backlash of differential gear 15 Preload of pinion bearing 16 Preload of side bearing 17 Back facial runout of bevel gear 18
Standard shim thickness for differential cage

Adjust 15.7 to 31.4 N {1,600 to 3,200 kg} 0.13 1.3

WA1200-6

60-33

Power train Differential

Unit: mm

No.

Item
Standard dimension

Criteria
Repair limit 8.5 159.84

Remedy

1 Thickness of side gear washer 2 Wear of oil seal contacting surface

9.0 160 (0/-0.100)

Replace

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

No. 1 2 3 4 5 6 7 8 9

Item
Clearance between planetary shaft and bearing Clearance between planetary gear and bearing Clearance between planetary shaft and bearing Clearance between planetary gear and bearing Clearance between ring gear hub and bearing Clearance between wheel hub and bearing Clearance between axle housing and bearing Clearance between wheel hub and bearing Ring gear mounting retainer thickness Standard dimension

Criteria
Tolerance Shaft Hole +0.018 0 90 0 -0.020 0 -0.035 155 -0.025 -0.075 +0.041 +0.025 99.982 +0.026 0 +0.025 -0.051 190.5 0 -0.005 +0.127 +0.051 479.425 +0.076 0 +0.076 -0.050 679.45 0 -0.130 -0.020 +0.051 409.575 -0.060 0 +0.051 -0.044 546.1 0 -0.114 Standard dimension Tolerance 40 12 Standard clearance 0.27 to 0.65 0.30 to 0.78 0.29 to 0.72 0.32 to 0.88 2.4 0.1 0.1 Standard clearance Allowable clearance

Remedy

-0.038 to 0 -0.075 to -0.010 -0.041 to -0.001 -0.076 to -0.005 -0.127 to -0.025 -0.206 to -0.050 -0.020 to 0.111 -0.165 to -0.044 Repair limit 39.6 11.1 Allowable clearance

Replace

10 Thrust shaft length (*) 11 12

Backlash between planetary gear and sun gear

Backlash between planetary gear and ring gear Backlash between planetary gear 13 and sun gear Backlash between planetary gear 14 and ring gear Standard thickness of shim for 15 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 system
Steering pump
Model: HPV160 + 160 + SAR(2)71 + 63 60-38

60-38

60-38

a See the section of switch pump for pump HPV160+160.

60-38

WA1200-6

Steering system Switch pump

Switch pump
Model: HPV160 + 160 + SAR(3)125 + 100 60-39

60-39

WA1200-6

60-39

Steering system Switch pump

Model: HPV160 + 160

60-40

60-40

WA1200-6

Steering system Steering demand valve

Steering demand valve

60-41

WA1200-6

60-41

Steering system Steering demand valve

Unit: mm

No.
Steering spool return spring

Item

Criteria
Standard dimension Installation Installation Free length length load 74.5 N 41.8 38.0 {7.6 kg} 8.8 N 20.9 13.2 {0.9 kg} 410 N 90.8 83.0 {41.8 kg} 182.4 N 24.0 22.19 {18.6 kg} 182.4 N 24.0 22.19 {18.6 kg} 590 N 39.5 35.7 {60.2 kg} 8.8 N 20.9 13.2 {0.9 kg} Repair limit Installation Free length load 58.8 N {6 kg} 7.0 N {0.71 kg} 328 N {33.4 kg} 145.1 N {14.8 kg} 145.1 N {14.8 kg} 471 N {40.8 kg} 7.0 N {0.71 kg}

Remedy

2 3 4 5 6 7

Load check valve spring Demand spool return spring Surge cut relief valve spring Main relief valve spring Overload relief valve spring Check valve return spring

Replace

60-42

WA1200-6

Steering system Diverter valve

Diverter valve

60-43

Unit: mm

No. 1

Item
Standard dimension

Criteria
Tolerance Standard clearance Allowable clearance

Remedy

3 4

Shaft Hole Clearance between body and spool -0.023 +0.015 40 -0.005 +0.007 Standard dimension Installation Installation Free length Spool return spring length load 217 N 122.6 84 {22.1 kg} 5.59 N Check valve spring 79.2 54.5 {0.57 kg} 4.9 N Check valve spring 79.2 57.5 {0.50 kg}

0.020 to 0.030 Tolerance Installation Free length load 206 N 120.7 {21.0 kg} 5.3 N 77.9 {0.54 kg} 4.6 N 77.9 {0.47 kg}

Replace

WA1200-6

60-43

Steering system Steering cylinder mount

Steering cylinder mount

60-4

Unit: mm

No. 1

Item
Clearance between bushing and pin at the connection of steering cylinder rod and the frame Clearance between bushing and Standard dimension 160 160 Boss width 120 (0/-0.25) 120 (0/-0.25) Standard dimension

Criteria
Tolerance Shaft Hole -0.043 +0.025 -0.106 0 -0.043 -0.106 +0.025 0 Hinge width 135 (+1/0) 135 (+1/0) Tolerance 0.5 Standard clearance 0.131 to 0.043 0.131 to 0.043 Allowable clearance 1.0 1.0

Remedy

2 pin at the connection of steering

cylinder bottom and the frame Connecting portion of steering cylinder and front frame Connecting portion of steering cylinder rod and rear frame

3 4

Standard clearance (clearance of a + b) 0 to 3.25 0 to 3.25 Repair limit

Replace

5 Spacer width

7.0

60-44

WA1200-6

Steering system Steering cylinder

Steering cylinder

60-45

Unit: mm

No. 1 2 3

Item
Clearance between steering cylinder rod and bushing Clearance between piston rod mounting pin and bushing Clearance between cylinder bottom mounting pin and bushing Shaft -0.043 140 -0.106 -0.043 160 -0.106 -0.043 160 -0.106 Standard dimension 225 Standard dimension

Criteria
Tolerance Hole +0.277 +0.061 +0.025 0 +0.025 0 Tolerance +0.2 0 Standard clearance Allowable clearance

Remedy

0.104 to 0.683 0.383 0.043 to 1.0 0.131 0.043 to 1.0 0.131 Repair limit

Replace

4 Cylinder bore

WA1200-6

60-45

Steering system Steering cylinder

a Each dimension indicates the one before bushing is mounted.

Unit: mm

No. 5
Steering cylinder

Portion
Inner diameter of bushing press fitting portion on the rod side Inner diameter of bushing press fitting portion on the bottom side

Basic dimension
255 (-0.036/-0.088) 255 (-0.036/-0.088)

60-46

WA1200-6

Steering system Emergency steering pump

Emergency steering pump

Model: SAM(3)100 + 100 60-47

60-47

Unit: mm

No. 1 2

Item
Clearance between gear case and side plate Clearance between needle bearing bore and gear shaft outside diameter Type SAM3-100 SAM3-100

Criteria
Standard clearance 0.10 to 0.15 0.0200.043 14 (0/-0.5) 13.7 to 23.5 Nm {1.4 to 2.4 kgm} Rotation speed (rpm) 2,000 Delivery pressure MPa {kg/cm2} 20.6 {210} Standard delivery (r/min.) 352 Allowable delivery (r/min.) 312 Allowable clearance 0.19

Remedy

Replace 0.075

3 Pin driving depth 4 Spline shaft rotating torque

Delivery oil EO10-CD Oil temperature: 45 to 55 C Type

SAM3-100

WA1200-6

60-47

Brake system Brake valve

Brake system
Brake valve
(R.H.) 60-48

60-48

60-48

Unit: mm

No. 1

Item
Clearance between pedal mounting hole and bracket hole Standard dimension

Criteria
Tolerance Shaft Hole -0.025 +0.1 10 -0.075 0 -0.025 +0.1 10 -0.075 0 Standard dimension Tolerance 0 30 -0.5 Standard dimension Installation Installation Free length length load 4.6 N 34 33.5 {0.47 kg} 11.8 N 46.3 46.0 {1.2 kg} 60.8 N 86.2 58 {6.2 kg} 17.7 N 17 16.5 {1.8 kg} 16.7 N 31.5 19.5 {1.7 kg} Standard clearance Allowable clearance

Remedy

2 Clearance between roller and pin 3 Outside diameter of roller

0.175 to 0.25 0.025 0.175 to 0.25 0.025 Repair limit 29.2 Repair limit Installation Free length load 33 45.3 78 16.2 28 Replace

4 Control spring

5 Control spring 6 Return spring 7 Spring 8 Return spring

60-48

WA1200-6

Brake system Brake valve

(L.H.)

60-49

Unit: mm

No. 1

Item
Clearance between pedal mounting hole and bracket hole Standard dimension

Criteria
Tolerance Shaft Hole -0.025 +0.1 10 -0.075 0 -0.025 +0.1 10 -0.075 0 Standard dimension Tolerance 0 30 -0.5 Standard dimension Installation Installation Free length length load 93.2 N 34 21.8 {9.5 kg} 45.9 N 46.3 34.3 {46.8 kg} 60.8 N 86.2 58 {6.2 kg} 16.7 N 31.5 19.5 {1.7 kg} Standard clearance Allowable clearance

Remedy

2 Clearance between roller and pin 3 Outside diameter of roller

0.175 to 0.25 0.025 0.175 to 0.25 0.025 Repair limit 29.2 Repair limit Installation Free length load 33 45.3 78 28 Replace

4 Control spring

5 Control spring 6 Return spring 7 Return spring

WA1200-6

60-49

Brake system Slack adjuster

Slack adjuster

60-50

Unit: mm

No. 1

Item
Clearance between body and piston Standard dimension

Criteria
Tolerance Shaft Hole -0.030 +0.074 55 -0.076 0 Standard dimension Installation Installation Free length length load 117.7 N 246 88 {12 kg} 123.6 N 44.8 38 {12.6 kg} Standard clearance Allowable clearance

Remedy

2 Slack adjuster spring

0.030 to 0.25 0.150 Repair limit Installation Free length load

Replace

3 Check valve spring

60-50

WA1200-6

Brake system Brake

Brake

60-51

Unit: mm

No.

Item

Criteria
Standard dimension Installation Installation Free length length load 1,600 N 124.9 104.8 {163 kg} Standard dimension Tolerance 3.1 6.7 850 839.5 864 Standard strain volume 0.1 0.3 0 -0.230 +0.140 0 +0.140 0 0.7 0.9 Repair limit Installation Free length load 1,520 N 123.0 {154.9 kg} Repair limit 2.85 6.2 Repair limit

Remedy

1 Return spring

2 Thickness of plate 3 Thickness of disc 4 Wear of seal contacting surface 5 6

Wear of piston seal contacting surface Wear of piston seal contacting surface

Replace

7 Strain of plate friction surface 8 Strain of disk friction surface

0.5 (maximum) 0.7 (maximum)

WA1200-6

60-51

Brake system Parking brake

Parking brake

60-52

Unit: mm

No.

Item
No.1 clutch spring (x14) No.2 clutch spring (x14) Total assembly thickness of 16 brake disks and 17 separator plates
Thickness

Criteria
Standard dimension Installation Installation Free length length load 1,008.5 N 132 83.8 {102.81 kg} 1,627.5 N 130 83.8 {165.9 kg} Standard dimension Tolerance 119.2 4.0 3.2 0.45 0.7 626.6 N {63.9 kg} 0.39 0.05 0.20 0.08 +0.25 0 0.16 176.5 N {18 kg} Repair limit Installation Free length load 958.1 N 128 {97.67 kg} 1,546.1 N 126.1 {157.61 kg} Repair limit 113.9 3.9 0.6 2.975 0.338 532.6 N {54.3 kg}

Remedy

2 3

4 Separate plate
Distortion Thickness Lining groove depth (one side) Lining thickness (one side)

Replace

5 Brake disc

Wave spring load (height: 3.2 mm)

60-52

WA1200-6

Brake system Parking brake

WA1200-6

60-53

Undercarriage and frame axle mount

Undercarriage and frame

axle mount

60-54

60-54

60-54

WA1200-6

Undercarriage and frame axle mount

Unit: mm

No.

Item
Clearance between shaft and hole of the front support (before bushing press fit) Clearance between shaft and hole Standard dimension 540 530

Criteria
Tolerance Shaft +4.000 0 -0.076 -0.185 +4.000 0 -0.076 -0.185 Hole +0.175 0 +0.522 -0.346 +0.175 0 +0.522 -0.346 Tolerance 0.2 -0.21 -0.35 0.1 0.1 Repair limit Standard Allowable clearance clearance -4.000 to +0.175 -0.270 to 0.707 -4.000 to +0.175 -0.270 to 0.707 1.6

Remedy

2 of the front support 3 4

(after bushing press fit) Clearance between shaft and hole of the rear support (before bushing press fit) Clearance between shaft and hole of the rear support (after bushing press fit)

540

Replace 1.6

530

Standard dimension

Repair limit

5 Thickness of thrust washer 6 Thickness of thrust plate 7 Thickness of rear bushing 8 Thickness of front bushing

8 53 5 5

WA1200-6

60-55

Undercarriage and frame Center hinge pin

Center hinge pin

60-56

60-56

WA1200-6

Undercarriage and frame Center hinge pin

Unit: mm

No.

Item
Clearance between lower hinge pin and bushing Clearance between lower hinge pin and spacer (small) Clearance between lower hinge pin and bearing Clearance between lower hinge pin and bearing (large) Clearance between lower hinge spacer (large) and bushing Clearance between front frame and upper hinge bearing Clearance between upper hinge pin and rear frame Clearance between upper hinge pin and bearing Clearance between front frame and lower hinge bearing Clearance between rear frame of upper hinge portion and bushing Clearance between upper hinge seal press-fit portion Clearance of lower hinge pin seal press-fit portion Clearance between lower hinge bushing and frame (upper side) Clearance between lower hinge bushing and frame (lower side) Standard dimension 228.46

Criteria
Tolerance Shaft Hole +0.078 0 +0.072 0 +0.025 0 +0.072 0 +0.099 0 -0.074 -0.126 +0.072 0 +0.072 0 -0.109 -0.166 +0.072 0 +0.072 0 +0.081 0 +0.072 0 +0.089 0 Tolerance 0.1 0.1 0.8 3.0 2.52 2.62 Repair limit Standard Allowable clearance clearance 0.050 to 0.157 0.050 to 1.0 0.151 0.050 to 0.104 0.050 to 1.0 0.151 0.056 to 0.236 -0.151 to -0.074 0.050 to 0.151 0.050 to 0.151 -0.217 to -0.109 0.050 to 0.151 -0.260 to -0.088 -0.260 to -0.079 -0.242 to -0.124 -0.325 to -0.179 Repair limit

Remedy

2 3 4 5 6 7 8 9 10 11 12 13 14

-0.050 -0.079 -0.050 228.46 -0.079 -0.050 228.46 -0.079 -0.050 228.46 -0.079 -0.056 305.0 -0.137 +0.025 269.875 0 -0.050 187.325 -0.079 -0.050 187.325 -0.079 +0.051 431.8 0 -0.050 248 -0.079 +0.26 210 +0.16 +0.260 310 +0.160 +0.242 250 +0.196 +0.325 325 +0.268 Standard dimension 134.5 224.5 45

Replace

15 Lower hinge spacer (small) height 16 Lower hinge spacer (large) height
Thickness of lower hinge and retainer Standard shim value for lower hinge 18 and retainer Standard shim value for lower hinge 19 and retainer Standard shim value for upper 20 hinge and retainer

17

Adjust

WA1200-6

60-57

Undercarriage and frame Center hinge pin

Front center hinge

Rear center hinge

60-58

WA1200-6

Hydraulic system No.1 work equipment pump

Hydraulic system
Model: HPV160 + 160

No.1 work equipment pump

60-59

60-59

60-59

WA1200-6

60-59

Hydraulic system No.1 work equipment pump

No.1 work equipment pump (HPV160 + 160)

60-60

60-60

WA1200-6

Hydraulic system No.1 work equipment pump

WA1200-6

60-61

Hydraulic system No.2 work equipment pump

No.2 work equipment pump

Model: HPV95 + 95 + SAL(2)40 60-62

60-62

60-62

WA1200-6

Hydraulic system No.2 work equipment pump

No.2 work equipment pump (HPV95 + 95)

60-63

WA1200-6

60-63

Hydraulic system No.2 work equipment pump

60-64

WA1200-6

Hydraulic system PPC relief valve

PPC relief valve

60-65

Unit: mm

No.

Item

Criteria
Standard dimension Installation Installation Free length length load 17.6 N 44.5 32.5 {1.79 kg} 37.0 N 31 26.7 {3.77 kg} Allowable limit Installation Free length load 13.7 N {1.4 kg} 29.6 N {3.0 kg}

Remedy

1 Main valve spring

Replace

2 Poppet spring

WA1200-6

60-65

Hydraulic system Pump control relief valve

Pump control relief valve

60-6

Unit: mm

No.

Item

Criteria
Standard dimension Installation Installation Free length length load 17.6 N 44.5 32.5 {1.79 kg} 37.0 N 31.0 26.7 {3.77 kg} Allowable limit Installation Free length load 13.7 N {1.4 kg} 29.6 N {3.0 kg}

Remedy

1 Main valve spring

Replace

2 Poppet spring

60-66

WA1200-6

Hydraulic system Work equipment control valve

Work equipment control valve

60-67

WA1200-6

60-67

Hydraulic system Work equipment control valve

Unit: mm

No.

Item

Criteria
Standard dimension Installation Installation Free length length load 431 N 69.9 63.0 {44.0 kg} 607.6 N 77.0 71.5 {62 kg} 61.6 N 79.7 78.5 {6.28 kg} 18.8 N 78.2 52.0 {1.92 kg} 137 N 53.0 42.1 {14.0 kg} 49.0 N 82.7 47.0 {5.0 kg} Allowable limit Installation Free length load 345 N {35.2 kg} 486.1 N {49.6 kg} 49.0 N {5.0 kg} 14.7 N {1.50 kg} 110 N {11.2 kg} 39.2 N {4.0 kg}

Remedy

1 Spool return spring

2 Spool return spring 3 Spool return spring 4 Check valve spring 5 Spring of float selector valve 6 Spring of unload valve

If damaged or deformed, replace spring

60-68

WA1200-6

Work equipment Work equipment linkage

Work equipment

Work equipment linkage

60-69

60-69

WA1200-6

60-69

Work equipment Work equipment linkage

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 Work equipment linkage

Unit: mm

No.

Item
Clearance between shaft hole bushing and pin of the both ends of the bucket link Clearance between bushing and Standard dimension 180 240

Criteria
Tolerance Shaft -0.043 -0.106 -0.050 -0.122 -0.056 -0.137 -0.043 -0.106 -0.043 -0.106 -0.050 -0.122 -0.050 -0.122 -0.050 -0.122 Hole +0.401 +0.309 +0.519 +0.421 +0.605 +0.493 +0.242 +0.196 +0.401 +0.309 +0.519 +0.421 +0.519 +0.421 +0.519 +0.421 Repair limit Standard Allowable clearance clearance 0.352 to 0.1 0.507 0.471 to 0.641 0.549 to 0.742 0.239 to 0.348 0.352 to 0.507 0.471 to 0.641 0.471 to 0.641 0.471 to 0.641 0.1

Remedy

2 pin at the connection of lift arm and 3 4 5 6 7 8

bucket Clearance between bushing and pin at the connection of lift arm and frame Clearance between bushing and pin at the connection of bucket cylinder rod and bell crank Clearance between bushing and pin at the connection of bucket cylinder bottom and frame Clearance between bushing and pin at the connection of bell crank and lift arm Clearance between bushing and pin at the connection of lift arm cylinder bottom and frame Clearance between bushing and pin at the connection of lift arm cylinder rod and lift arm Connection portion of bucket cylinder and bell crank Connection portion of lift arm and frame Connection portion of lift arm and bucket Connection portion of bucket link and bucket Connection portion of bell crank and bucket link Connection portion of lift arm cylinder and frame Connection portion of bell crank and lift arm Connection portion of bucket cylinder and frame Connection portion of lift arm and lift arm cylinder

280

0.1 Replace Replace when the pin has galling too.

180

0.1

180

0.1

240

0.1

240

0.1

240 Pin length 393 0.3 655 0.3 594 0.3 479 0.3 443 0.3 580.5 0.3 594 0.3 430 0.3 479 0.3

0.1 Collar width c 91.3 0.1 174.7 0.1 121.8 0.1 109.3 0.1 91.3 0.1 183.3 0.1 121.8 0.1 109.3 0.1 101.8 0.1 Replace the bushing and the collar when the clearance of d + e reaches 2.5 mm.

9 10 11 12 13 14 15 16 17

Bush width a 209.5 0.1 304.5 0.1 349.4 0.1 259.5 0.1 259.5 0.1 274.4 0.1 349.4 0.1 209.5 0.1 274.4 0.1

Collar width b 91.3 0.1 174.7 0.1 121.8 0.1 109.3 0.1 91.3 0.1 121.8 0.1 121.8 0.1 109.3 0.1 101.8 0.1

Standard dimension

Repair limit 340 12 40 30 Replace

18 Wear of bucket teeth 19 Wear of wear plate 20 Wear of edge protector 21 Wear of side edge protector

504 70 189 83

WA1200-6

60-71

Work equipment Work equipment linkage

Front frame

Lift arm cylinder

Lift arm, bell crank, bucket link

Bucket cylinder

Bucket

60-72

WA1200-6

Work equipment Work equipment linkage

a Each dimension indicates the one before bushing is mounted.

Unit: mm

No. 22 23 Front frame 24 25 26

Lift arm

Item
Inner diameter of lift arm mounting pin portion inner diameter of pin mounting portion on the bucket cylinder bottom side Inner diameter of pin mounting portion on the lift arm cylinder bottom side Inner diameter of front frame mounting portion Inner diameter of pin mounting portion on the lift arm cylinder rod side Inner diameter of bell crank mounting pin portion Inner diameter of bucket mounting pin portion Inner diameter of lift arm mounting portion Bore of pin mounting portion on the bucket cylinder rod side Inner diameter of bucket link mounting pin portion Inner diameter of bell crank mounting portion Bucket link Inner diameter of bucket mounting portion Inner diameter of pin mounting portion on the rod side Lift arm cylinder Inner diameter of pin mounting portion on the bottom side Inner diameter of pin mounting portion on the rod side Bucket cylinder Inner diameter of pin mounting portion on the bottom side Inner diameter of bucket link mounting pin portion Bucket Inner diameter of lift arm mounting portion 340 (+0.089/0) 230 (+0.072/0) 300 (+0.081/0) 340 (+0.089/0) 300 (+0.081/0) 300 (+0.081/0) 300 (+0.081/0) 300 (+0.081/0) 230 (+0.072/0) 230 (+0.072/0) 230 (+0.072/0) 230 (+0.072/0) 300 (+0.081/0) 300 (+0.081/0) 230 (+0.072/0) 230 (+0.072/0) 230 (+0.072/0) 300 (+0.081/0)

27 28 29 30 Bell crank 31 32 33 34 35 36 37 38 39

WA1200-6

60-73

Work equipment Bucket positioner, remote positioner

Bucket positioner, remote positioner

60-74

Unit: mm

No. 1 2

Item
Clearance of bucket positioner switch Bucket positioner protector to switch tip

Criteria
3 to 5

Remedy
Adjust

0.5 to 1 See the Inspection and Adjustment section for adjustment.

3 Lift arm angle sensor

60-74

WA1200-6

Work equipment Work equipment cylinder

Work equipment cylinder

Lift arm cylinder 60-75

60-75

Unit: mm

No.

Item
Clearance between lift arm cylinder rod and bushing Clearance between piston rod mounting pin and bushing Clearance between cylinder bottom mounting pin and bushing Standard dimension

Criteria
Tolerance Shaft Hole +0.247 +0.034 +0.519 +0.421 +0.519 +0.421 Tolerance +0.2 0 Repair limit Standard Allowable clearance clearance 0.084 to 0.669 0.369 0.471 to 1.0 0.641 0.471 to 1.0 0.641 Repair limit

Remedy

2 3

-0.050 240 -0.122 -0.050 240 -0.122 -0.050 240 -0.122 Standard dimension 360

Replace

4 Cylinder bore

WA1200-6

60-75

Work equipment Work equipment cylinder

Bucket cylinder

60-76

Unit: mm

No.

Item
Clearance between bucket cylinder rod and bushing Clearance between piston rod mounting pin and bushing Clearance between cylinder bottom mounting pin and bushing Standard dimension

Criteria
Tolerance Shaft Hole +0.216 +0.048 +0.401 +0.309 +0.401 +0.309 Tolerance +0.2 0 Repair limit Standard Allowable clearance clearance 0.091 to 0.622 0.322 0.352 to 1.0 0.507 0.352 to 1.0 0.507 Repair limit

Remedy

2 3

-0.043 180 -0.106 -0.043 180 -0.106 -0.043 180 -0.106 Standard dimension 300

Replace

4 Cylinder bore

60-76

WA1200-6

Electrical system Work equipment control lever

Electrical system

Work equipment control lever

a Do not disassemble this part. If it is disassembled, it needs to be adjusted to maintain its performance.

60-7

60-7

WA1200-6

60-77

Electrical system Work equipment control lever

60-78

WA1200-6

SEN0547531-00

80-1

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

8-01

Machine model
WA1200-6

Serial number
60001 and up

80 Appendix

80-1

WA1200-6

80-1

Contents

Contents
80 Appendix Air conditioner ......................................................................................................................... Precautions for refrigerant ................................................................................................... Configuration and function of refrigeration cycle.................................................................. Outline of refrigeration cycle ................................................................................................ Control system ..................................................................................................................... Air conditioner components ................................................................................................. Compressor ......................................................................................................................... Electric fan and condenser .................................................................................................. Receiver drier....................................................................................................................... Service tools ........................................................................................................................ Troubleshooting procedures ................................................................................................ Interview and confirmation of failure symptom..................................................................... Basic checks ........................................................................................................................ Troubleshooting ................................................................................................................... Checking of refrigeration cycle............................................................................................. Troubleshooting for unusual noise....................................................................................... Electrical system .................................................................................................................. Parts replacement................................................................................................................ Periodic inspection and maintenance .................................................................................. Testing and adjusting compressor belt tension.................................................................... 80808080808080808080808080808080808080803 3 4 5 7 11 18 19 21 22 29 30 31 32 38 46 47 49 52 56

80-2

80-2

WA1200-6

Air conditioner Precautions for refrigerant

Air conditioner
k

Precautions for refrigerant

Collect the air conditioner refrigerant (R134a) from air conditioner circuit before disconnecting 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 atmosphere. 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. Accordingly, 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 refrigerant (R134a). Collecting and filling work must be conducted by a qualifier person.

80-3

80-3

WA1200-6

80-3

Air conditioner Configuration and function of refrigeration cycle

Configuration and function of refrigeration cycle

Cycle (Component) Location Compression (Compressor) Engine compartment Circulates refrigerant gas and increases its temperature and pressure so that it can be liquefied easily in condenser. (Compression of refrigerant) Gas o Gas Adiabatic compression Condensation (Condenser) Front of radiator Expansion (Expansion valve) In operator cab (Built in air conditioner unit) Lowers temperature and pressure of refrigerant liquid and gas for easy evaporation with throttle. Controls flow rate, too. (Throttle of refrigerant) Liquid o Liquid and gas Adiabatic expansion Evaporation (Evaporator) In operator cab (Built in air conditioner unit) Evaporates refrigerant to absorb heat from air around evaporator, and cool the air. (Evaporation of refrigerant) Liquid and gas o Gas Cnstant pressure change

80-4

Function

Condenses refrigerant to discharge heat absorbed in evaporator. (condensation of refrigerant) Gas o Liquid Cnstant pressure change

State of refrigerant

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 compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into a state where it can be easily liquefied at the ambient temperature. The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and pressure at which it can be easily liquefied when cooled to the ambient temperature. 2. Condensation (Condenser) The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from the compressor. The heat released to the outside from the condenser is called condensation heat. The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the compressor. The refrigerant liquefied in the condenser is sent to the receiver drier, where moisture is removed. In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist. The temperature (condensation temperature) and the pressure (condensation pressure) at which the gaseous refrigerant is liquefied are proportional to each other. Reference: The pressure varies depending on the condensation temperature of the refrigerant. 3. Expansion (Expansion valve) The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily evaporated by the throttle action (*1). The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it is sent to the evaporator is called expansion. The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate simultaneously. The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure). The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is supplied to the evaporator. (*1) Throttle action If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to the flow will be generated. The liquid expands when it passes through the narrow section and rushes into the passage where the sectional area is larger, and consequently, its pressure and temperature are reduced. No heat is transferred from or to the outside during the throttle action. 4. Evaporation (Evaporator) The evaporator evaporates the liquid refrigerant (superheated vapor). The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation heat) from the air around the cooling fins (air in the cab). After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the temperature inside the cab. The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant in the evaporator The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid refrigerant is evaporated are proportional to each other. The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature. Relationship between refrigerant and defective 80-5 air conditioning q The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat from inside the cab. q If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.

WA1200-6

80-5

Air conditioner Outline of refrigeration cycle

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. 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 defective air conditioning.

80-6

WA1200-6

Air conditioner Control system

Control system
To make best use of the performance and maintain a comfortable environment in the operator's cab, the air conditioner has various control systems including the air temperature control, air flow control, air vent mode selection, etc.. 1. Outline of controls 1) Control panel a The control panel is integrated with the controller.
q

80-7

80-7

1. Temperature control switch q This switch allows adjustment of the air temperature 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 "Dehumidification" 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 The function of the main controls for the air conditioner are shown in the following table.
Item
q

Control details This temperature control is performed by automatically switching ON and OFF the compressor at a set temperature depending on the temperature of the air cooled by the evaporator, which is monitored using a thermistor. This air flow control is achieved by adjusting the blower motor speed in four levels. This changeover is realized by controlling the fresh air and recirculated air selector damper. This selector is realized by controlling the air vent selection damper for cooling and heating. This control is performed to prevent frosting of the evaporator. A thermistor is used. This control is used to detect abnormal refrigerant pressures.

1. Temperature control 2. Air flow control 3. FRESH/RECIRC air changeover control 4. Anti-icing control 5. Compressor control
q q q q q q

2. Temperature control (thermistor) 80-8 Thermistor (1) is a semiconductor whose resistance varies significantly with temperature. As shown in the drawing, its resistance decreases as the temperature rises, and its resistance increases as the temperature lowers. Thermistor (1) is installed to the rear of the evaporator 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 thermistor are compared at the air conditioner amplifier, 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 The flow of air blown into the cab is controlled by changing the blower motor speed. The blower motor is a ferrite motor, and its speed (air flow) is controlled by changing the voltage using resistors.

80-9 5. Anti-icing control When warm air passes through the evaporator fins, the moisture in the air condenses as the air is cooled, generating waterdrops on the evaporator fins. 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 evaporator, and the temperature signal is used to turn off the air compressor before icing occurs at the evaporator.

[Reference] 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 = KV/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.

80-9 4. FRESH/RECIRC air changeover control 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

80-10 6. Compressor control Judgment of abnormal refrigerant pressures If an abnormal pressure is detected by the pressure switch installed to the high-pressure side of the refrigerant cycle, the compressor is stopped to prevent problems in the refrigeration cycle components. Commonly, the refrigerant pressure is detected by a pressure switch installed between the receiver tank and the expansion valve on the high-pressure side.

1] Detecting abnormally high pressures If the pressure in the refrigeration cycle becomes abnormally high, it may cause failure or damage of the components. The pressure switch becomes OFF state if it detects a high pressure exceeding approx. 3.1 MPa {32 kg/cm2}. 2] Detecting abnormally low pressures If the refrigerant in the refrigeration cycle 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 Air conditioner components

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 Specifications
Refrigerant Refrigerant refill capacity (g) R134a 1,300 - 1,500

80-12

80-12

WA1200-6

Air conditioner Air conditioner components

Air conditioner unit

80-13

19. Evaporator 20. Heater core 21. Expansion valve 22. Thermistor 23. Servomotor 24. Air mix door 24-1. Cool door 24-2. Hot door

25. Water valve 26. Blower fan and blower motor 27. Blower resistor F: Refrigerant inlet (from condenser) G: Refrigerant outlet (to condenser) H: Hot water inlet J: Hot water outlet

WA1200-6

80-13

Air conditioner Air conditioner components

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 Air conditioner components

Vent selector box

80-15

32. Vent (mode) selector servomotor 33. Vent (mode) selector door 80-15 Functions of components 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 Air conditioner components

Expansion valve

A: When evaporator outlet temperature is high B: When evaporator outlet temperature is low C: From receiver drier (high-pressure refrigerant) D: To compressor (low-pressure refrigerant) 19. Evaporator 21. Expansion valve 1a. Needle valve 1a-1. Diaphragm 1a-2. Thermoprobe 1b. Spring 34. Refrigerant gas 80-16 Outline Expansion valve (21) converts high-pressure and high-temperature liquid refrigerant sent from the receiver drier to a mist of low-pressure and low-temperature refrigerant through throttle action. q It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in the cab. q The temperature of the air blown out of the air vent is adjusted according to the volume of refrigerant circulating in evaporator (19).
q

80-16 Structure q Box-type expansion valve (21) consists of needle valve (1a), spring (1b), etc. q Refrigerant gas (34) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of needle valve (1a). q The opening level of the needle valve (1a) is determined based on the balance between the reaction force exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (34) pushing the needle valve (1a) through the diaphragm (1a-1) in a leftward direction. q The refrigerant flow rate flowing from the receiver drier to evaporator (19) is determined based on the opening of needle valve (1a).

80-16

WA1200-6

Air conditioner Air conditioner components

Operation 80-17 q Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (19). q The temperature of the refrigerant that has passed through evaporator (19) is transferred to the refrigerant gas (34) in the diaphragm chamber (hatched area) through the thermoprobe (1a-2). q The pressure of the refrigerant gas (34) sealed in the diaphragm chamber (hatched area) changes in response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg) pushing the needle valve (1a). q The opening level of the needle valve (1a) is determined based on the balance between the reaction force exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (34) pushing the needle valve (1a) through the diaphragm (1a-1) in a leftward direction. When outlet temperature of evaporator (19) is 80-17 high: [When it is not cooled yet: Condition (A) in the 80-17 figure] q The pressure of the refrigerant gas (34) in the diaphragm chamber is high and the volume is increased. q The force (Fg) of the refrigerant gas (34) pushing the needle valve (1a) increases and moves the needle valve (1a) to the left. q As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the evaporator (19) is increased, resulting in increased cooling capacity. When outlet temperature of evaporator (19) is 80-17 low: [When it is cooled already: Condition (B) in the 80-17 figure] q The pressure of the refrigerant gas (34) in the diaphragm chamber is low and the volume is decreased. 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 reduced and the refrigerant flow rate to the evaporator (19) is reduced, resulting in decreased cooling capacity.

Pressure switch a This pressure switch is installed to the air conditioner tube on the floor. q Pressure switch (8) becomes "OFF" when the refrigerant circuit pressure becomes abnormally low or abnormally high. q When the pressure switch becomes "OFF", the air conditioner controller sets the compressor clutch relay to "OFF". As a result, the compressor's magnetic clutch is released and air conditioner components are protected.

a LA or lower: Abnormally low pressure a HA or higher: Abnormally high pressure LA: 0.20 MPa {2 kg/cm2} LB: 0.02 MPa {0.2 kg/cm2} HA: 3.14 MPa {32 kg/cm2} HB: 0.59 MPa {6 kg/cm2}

WA1200-6

80-17

Air conditioner Compressor

Compressor

80-18

A: Refrigerant inlet (from air conditioner unit) B: Refrigerant outlet (to condenser) 1. Pulley 2. Magnet clutch 3. Relief valve

80-18 Function q The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator to convert it into mist of high-pressure and high-temperature refrigerant so that it 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 pressure. q When the magnet clutch is engaged, the power of the engine rotates the compressor shaft along with pulley (1) to drive the compressor. Specifications
Number of cylinders - bore x stroke (mm) Piston capacity (cc/rev) Allowable maximum speed (rpm) Compressor oil Compressor oil refill capacity (cc) 10 - 29.5x22.7 155.3 6,000 Denso: ND-OIL8 (For R134a) 220

80-18

80-18

WA1200-6

Air conditioner Electric fan and condenser

Electric fan and condenser

80-19

1. Electric fan 2. Electric fan motor 3. Condenser A: Refrigerant inlet (from compressor) B: Refrigerant outlet (to receiver drier)
q q

Specifications
Fin pitch (mm) Core height x width x thickness (mm) Max. operating pressure (MPa {kg/cm2}) 4.0 311.2x346x44 3.6 {36}

80-19

Electric fan motor (2) drives electric fan (1) for forced-cooling of condenser (3). If the condenser fins are crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction of refrigerant becomes impossible. If the heat exchange efficiency is reduced, pressure 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

80-20 Function The condenser in the refrigeration cycle is used for liquefying gaseous refrigerant, by forcibly causing heat exchange between the compressed, high-temperature and high-pressure gaseous refrigerant and outside air, by using the fan, etc. The amount of heat removed from the gaseous refrigerant at the condenser depends on the amount of heat absorbed from the cabin air at the evaporator and the workload of the compressor compressing the gas. Therefore, the heat dissipation effect of the condenser has a direct and major effect on cooling of the cabin air.

2. Pressure switch The pressure switch becomes ON or OFF according to the refrigerant pressure. ON: 1.52 MPa {15.5 kg/cm2} OFF: 1.23 MPa {12.5 kg/cm2}

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
80-21 Function q The receiver drier temporarily stores the high-pressure and high-temperature liquid refrigerant from the condenser so that it can be supplied 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 liquefied completely ever when it contains air bubbles 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. Specifications
Effective volume (cc) Weight of desiccating agent (g) 370 290

80-21

A: Refrigerant inlet (from condenser) B: Refrigerant outlet (to air conditioner unit)

WA1200-6

80-21

Air conditioner Service tools

Service tools
1. Service tool kit Measuring tools for testing operating pressure
Symbol
q

80-2
Part name Service tool kit

Part No. 799-703-1200

The service tool kit consists of a gauge manifold and connecting hoses. a Use the service tool kit designed for R134a to measure the operating pressure of air conditioner systems charged with R134a. Connection parts of the service tool kit for R134a differ in diameters to prevent wrong connections.

1. Gauge manifold 2. High-pressure hose (red) (inside diameter of fitting: 12 mm) 3. Low-pressure hose (blue) (inside diameter of fitting: 10 mm) 4(*). Center hose (green) (inside diameter of fitting: 10 mm) 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

*: Center hose (4), service can valve (7), and service can T-joint (8) are tools used only for charging with refrigerant. Ask a qualified shop for collecting, adding, and filling operation of refrigerant (R134a). See "Precautions for refrigerant".

80-22

WA1200-6

Air conditioner Service tools

2. Gauge manifold q The gauge manifold is used for testing operating 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 1-1. Low-pressure gauge 1-2. High-pressure gauge 1-3. High-pressure valve dial (HI)

1-4. Low-pressure valve dial (LO) 1-5. High-pressure valve (HI) 1-6. Low-pressure valve (LO) 1-7. Built-in air purge valve

WA1200-6

80-23

Air conditioner Service tools

2) Handling of gauge manifold By combining opening and closing of the high- and low-pressure valve using the dials, 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"

4] When both low-pressure valve dial (LO) and high-pressure valve dial (HI) are set to "Open"

2] When low-pressure valve dial (LO) is set to "Open" and high-pressure valve dial (HI) is set to "Closed"

3] When low-pressure valve dial (LO) is set to "Closed" and high-pressure valve dial (HI) is set to "Open"

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. q Red (2): To high-pressure side of gauge manifold 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 entry 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 charging with refrigerant. Ask a qualified shop for collecting, adding, and filling operation of refrigerant (R134a). See "Precautions for refrigerant".

80-24

WA1200-6

Air conditioner Service tools

4) Quick joints Quick joint (5) (with check valve) allows the connection of gauge manifold hose (2) and service valve (10) of the air conditioner piping 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 procedures are basically the same for the low-pressure hose.

a It may be difficult to connect if refrigerant remains in the hose. In this case, press part C to release the remaining pressure in the 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 Connect service tools such as gauge manifold (1) and hoses according to the following procedure. 1) Set high-pressure valve dial (HI) (1-3) and low-pressure valve dial (LO) (1-4) of gauge manifold (1) to "Closed". 2) Connect red hose (2) to the HI side and the blue hose (3) to the LO side of gauge manifold (1). 3) Connect quick joints (5) and (6) to hoses (2) and (3) respectively. a Note that quick joints for low-pressure and high-pressure have different outside diameters at their fittings. High-pressure quick joint (5): outside diameter of fitting 12 mm Low-pressure quick joint: outside diameter of fitting 10 mm

4) Connect quick joint (5) to service valve (10) at the high-pressure side piping, and connect quick joint (6) to service valve (11) at the low-pressure side piping. a For connecting procedures, see "2. 4) Quick joints". a Depending on the machine, the service valves may be provided on compressor (12). a Be sure to use quick joints for connection of both high-pressure and low-pressure hoses. If the quick joint is not used for connection of one hose, air may leak in and vacuum will not be maintained. (The check valve built in the quick joint cannot hold vacuum.) k Take care not to connect the hoses to high-pressure and low pressure ports of the gauge manifold reversely.

80-26

WA1200-6

Air conditioner Service tools

4. Gas leak detector Tools for testing refrigerant gas leakage

Symbol
q

Part No. 799-703-1401

Part name Gas leak detector

a The conventional halide torch leak tester cannot detect R134a refrigerant, which does not contain chlorine.

This is an electric tester used for detecting refrigerant gas leaking from the refrigeration cycle at connections, etc. Place the probe end to the place to check for leakage, and slowly move the probe to find the leaking point. The sound and light flashing becomes quick when the probe comes close to the leaking point. This gas leak detector can be used to detect gas leakage of both R134a and conventional R12.

1. Battery charger 2. Internal battery 3. Sensor (under cover) 4. Speaker

5. Sensitivity selector switch 6. Suction probe 7. Check leak bottle 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 Commercially Belt tension gauge available

Belt tension gauge (1) can be remote-controlled by connecting remote cable (2), to facilitate work 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
q

80-29

Air conditioner failures can be generally classified into two types; refrigeration cycle problems and electrical problems. Troubleshooting by following the basic procedures are explained below. 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

Before performing troubleshooting, the symptom and occurring conditions of the problem must be carefully checked. You should hear from the operator about the conditions when the problem occurs, especially when it occurs sporadically or the symptom cannot be reproduced at the workshop. "Interviewing" is essential. <Important interview questions> q Which o Model, serial number q When o Date, time, and frequency of occurrence 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

80-30

WA1200-6

Air conditioner Basic checks

Basic checks
1. Checking control mechanism Operate the switches on control panel (1) to check if they work smoothly and positively. a Inspect fuses as necessary.

80-31

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
1. Cooling trouble 1) Insufficient air flow q Check the operation of blower motor
No. Details of problem
q q q q q q q

80-32

Cause Clogged recirculation air filter Clogged fresh air filter Obstacle at air intake Deformed or damaged blower Frost on evaporator Dirt on evaporator Dropped power supply voltage Defective contact at battery terminals Defective blower motor Defective blower Hi relay Open circuit in resistor (rotates only in Hi-speed setting) Blown fuse Defective power maximizing relay on machine Defective blower motor Interference of blower with case Defective blower switch Defective chassis ground Defective wiring or disconnection of connectors
q q q q q

Blower motor rotates normal but air flow is insufficient.

q q q q q q q q q q q q q

Blower motor does not rotate normally.

q q q q q q

Remedy Clean recirculation air filter. Clean fresh air filter. Remove obstacles. Replace blower. Turn off air conditioner to let the ice melt, and then go to "Cause and remedy A". Clean evaporator surface. Check battery charging system. Correct battery terminals. Replace blower motor. Replace blower Hi relay. Replace resistor. Replace fuse, and then go to "Cause and remedy B". Replace power maximizing relay. Replace blower motor. Correct interference. Replace panel. Improve grounding. Check wiring.

Blower motor does not rotate.

q q q q q

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.
No. Details of problem
q q q

Cause Broken or slipping V-belt Defective compressor Defective magnetic clutch

Remedy
q q q

Compressor does not run.

q

Clutch is not engaged due to defective electrical system.

Replace V-belt Replace compressor Repair or replace magnet clutch, or. go to "Cause and remedy D-1". Check wiring, and the go to "Cause and remedy D-2".

Compressor runs normally. Compressor pressure is normal

a Connect service tools to check if compressor pressure is normal, and then go to No. 3 or No. 4
q q q

Outside air leaking in cab Airmix linkage disconnected Pressure of low-pressure circuit is too high. (approx. 0.29 MPa {3 kg/cm2} or higher) Pressure of high-pressure circuit is too low. (does not exceed approx. 0.98 MPa {10 kg/cm2}) Pressure of low-pressure circuit is too low. (drops below approx. 0.05 MPa {0.5 kg/cm2}) Pressure of both high-pressure and low-pressure circuits is too high. Pressure of both high-pressure and low-pressure circuits is too low.

Close windows and doors, or adjust FRESH/RECIRC air changeover damper. Reset airmix linkage. Go to "Cause and remedy C-2". Go to "Cause and remedy C-3".

Compressor pressure is abnormal.

Go to "Cause and remedy C-4". Go to "Cause and remedy C-5". Lack of refrigerant

q q k

q q

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

No. 1 2 Details of problem Cut-off of high-pressure circuit Cut-off of low-pressure circuit
q q

Cause Go to "Cause and remedy C-1". Go to "Cause and remedy C-3".

Remedy

WA1200-6

80-33

Air conditioner Troubleshooting

Cause and remedy

No. Cause <Mixed defroster and face vent type> Defective magnet clutch circuit Defective frost sensor wiring Defective frost sensor characteristics Defective adjustment of gap between frost sensor and evaporator (poor sensitivity)
q q q q q q q

Remedy Check magnet clutch circuit or replace relay. Check for short circuit and repair. Check sensor characteristics or replace sensor. Adjusted gap: 12 5 mm (See Fig. 1) Check magnet clutch circuit or replace relay. Check for short circuit and repair. Check thermostat operation or replace thermostat. Replace Replace blower motor. Repair Repair or replace Clean fins (wash fins with water). Remove excessive refrigerant. Collect all refrigerant, evacuate the system, and then refill with proper quantity of refrigerant. Remove excessive refrigerant.

Voltage is applied to magnet clutch. A

<Independent defroster and face vents type> q Defective magnetic clutch circuit
q q

q q

Defective thermostat wiring Malfunction of thermostat Defective magnet clutch Blower motor locked Incorrect wiring Short circuit in wiring Abnormally high outside air temperature Insufficient cooling at condenser (fins clogged with dirt or mud) Filling too much with refrigerant Air in refrigerant cycle Filling too much with refrigerant Damaged cylinder head gasket

Voltage is not applied to magnet clutch. B

q q q q q q

q q q q q

q q

q q

Defective sor

compres-

Breakage of inlet valve Foreign matter caught in inlet valve

Replace compressor.

Expansion valve opening too wide

Defective valve Defective contact of temperature sensing bulb

q q

Replace Repair

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".

Fig. 1

80-34

WA1200-6

Air conditioner Troubleshooting

No.
q q

Cause Abnormally low outside air temperature Lack of refrigerant

q q

Remedy Refill with refrigerant to specified level. Perform a leak test, repair leaking point, and then refill with refrigerant.

Swash plate shoe locked 3

q

Defective compressor

Piston locked Defective inlet or outlet valve Clogged valve

Replace compressor.

q q q

Replace valve. Replace valve. Replace valve and receiver, and then evacuate system thoroughly. Refill with refrigerant to specified level. Perform a leak test, repair leaking point, and then refill with refrigerant. Replace receiver drier. Replace piping. Replace valve. Replace valve.

Defective valve

expansion

Gas leak at temperature sensing bulb Valve temporarily clogged due to icing

C
q q

Abnormally low outside air temperature Lack of refrigerant

q q

Clogging in refrigeration cycle Clogged valve.

q q q q q

Replace valve and receiver, and then evacuate system 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 refrigerant. 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". Valve temporarily clogged due to icing

Defective valve

expansion

Gas leak at temperature sensing bulb

WA1200-6

80-35

Air conditioner Troubleshooting

No.
q q

Cause Open circuit in stator coil Excessive air gap between rotor and stator Broken or missing key

q q q q q q q q q q q q q

Remedy Replace Repair or replace Replace key. Remove oil. Replace Charge Overhaul them. Replace control panel. Replace control panel. Replace Replace Replace (Go to troubleshooting No. C-1.)

Oily clutch surface

q

Slipping clutch Layer short in coil Dropped battery voltage

q q q q q q

2
q

Foreign matter caught between rotor and stator Defective air conditioner switch Defective blower switch Defective compressor clutch relay Defective thermosensor Defective refrigerant pressure switch for high-pressure or low-pressure circuit Abnormally high refrigerant pressure (2.5 MPa {25 kg/cm2} or Abnormally high refrigerhigher) ant pressure of high-presAbnormally low refrigerant sure circuit pressure (below 1.0 MPa {10 kg/cm2})

(Go to troubleshooting No. C-4.)

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
No. Details of problem Engine coolant temperature is normal but heating is insufficient. Low engine coolant temperature Temperature control LED is operating normally. Temperature control LED is not operating normally.
q q q q q q q q q q

Cause
q

Air in hot water circuit Clogged or bent piping Low engine coolant level Broken heater core

q q q

Remedy Bleed air from hot water circuit. Repair or replace Add coolant to specified level. Replace heater core. Close windows and doors. Reset temperature control linkage. Remove foreign matter. Check wiring. Replace servomotor.

2 3 4

Abnormally low outside air tempera ture q Outside air leaking in cab Temperature control linkage discon- q nected Foreign matter caught in linkage q Defective wiring, open circuit, defecq tive contact of connector q Defective servomotor

3) Water leakage into cab

No. 1 Details of problem Water leakage into cab Cause Clogging of drain hole
q

Remedy Clean

4) Defective FRESH/RECIRC air changeover

No. 1 Details of problem FRESH/RECIRC servomotor is normal. FRESH/RECIRC servomotor is abnormal.
q q

Cause Linkage disconnected Defective wiring, open circuit, defective contact of connector Defective servomotor Foreign matter caught in
q

Remedy Reset linkage. Check wiring. Replace servomotor. Remove foreign material.

q q q

q q

WA1200-6

80-37

Air conditioner Checking of refrigeration cycle

Checking of refrigeration cycle

1. Measuring by using gauge manifold Use the gauge manifold to measure the refrigerant pressure of high-pressure and low-pressure sides of the refrigeration cycle under the following conditions when performing troubleshooting. a Connect the gauge manifold. For details, see "Service tools, 3. Connection of service tool". <Conditions> After performing warm-up operation of the engine, take measurements under the following conditions. q Doors: fully open q FRESH/RECIRC air changeover: RECIRC q Engine speed: 1,500 rpm q Temperature at air conditioner suction port: 30 C35 C q Blower speed: HI q Temperature control: max cool a Reading on the gauge manifold may somewhat differ depending on the conditions. 1) When refrigeration cycle is normal Under above conditions; Pressure of low-pressure side: 0.150.25 MPa {1525 kg/cm2} Pressure of high-pressure side: 1.371.57 MPa {1416 kg/cm2} a Gauge in the drawing is calibrated in SI units, however, the actual gauge is calibrated also in conventional units.

80-38
2) Lack of charged refrigerant q Symptom 1] Pressure of both high-pressure and low-pressure sides is low. 2] Continuous flow of bubbles can be seen through sight glass. 3] Insufficient cooling q Cause 1] Lach of refrigerant 2] Leakage of gas q Points of remedy 1] Checking for gas leakage and repairing 2] Refill with refrigerant

3) Excessive refrigerant and insufficient cooling at condenser q Symptom 1] Pressure of both high-pressure and 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 (electric fan, etc.).

80-38

WA1200-6

Air conditioner Checking of refrigeration cycle

4) Water in refrigeration cycle q Symptom 1] Low-pressure gauge gradually reads negative pressure after certain period of operation. q Cause 1] Entry of water q Points of remedy 1] Replace receiver tank. 2] Thoroughly evacuate system to remove water before refilling with refrigerant.

6) Refrigerant does not circulate (clogging in refrigeration cycle). q Symptom 1] If clogged completely, low-pressure gauge reads negative pressure immediately. If partially clogged, low-pressure gauge reads negative pressure gradually. 2] Temperatures across the clogged part are different. q Cause 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. 2] Pressure of high- and low-pressure sides become the same as soon as the air conditioner is turned off. q Cause 1] Defective compressor q Points of remedy 1] Check and repair compressor.

7) Air in refrigeration cycle q Symptom 1] Pressure of both high-pressure and low-pressure sides is high. 2] Low-pressure side piping is not cold when touched. 3] Bubble can be seen through the sight glass. q Cause 1] Entry of air q Points of remedy 1] Replace refrigerant. 2] Thoroughly evacuate the system.

WA1200-6

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Air conditioner Checking of refrigeration cycle

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

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Air conditioner Checking of refrigeration cycle

2. Troubleshooting chart
No. Symptom Location Condition Probable cause Defective compression at compressor Defective valve or excessive opening (defective adjustment) Remedy Pressure of High- and low-pressure sides Compressor become the same as soon as the compressor turns off. Pressure of both highand low-pressure sides is high, low-pressure Pressure of low-pressure side Expansion valve hose and service valve of low-pressure side are is too high (above abnormally cold, and approx. 0.3 MPa frost (dew) adheres to 2 {3 kg/cm }). piping.

Replace compressor.

Replace expansion valve.

Defective contact of temperaSeizure of temperature sensing ture sensing bulb bulb (moved from installed position) Correct amount of refrigerant. Clean (wash with water), check, or repair condenser fins. Check and repair cooling system of machine (electric fan, radiator, etc.). Retighten or replace.

Refrigeration cycle

Pressure of both high- Excessive refrigerant and low-pressure sides is high, and pressure of low-pressure side drops Defective cooling of conwhen condenser is forc- denser ibly cooled. Loose or broken fan belt Condenser cooling fan does not draw in enough air (insufficient cooling air flow).

Condenser

Defective fan motor or slipping Replace motor or fix fan. fan Fan installed in wrong direc- Reinstall fan in correct direction tion. Fan shroud missing Condenser fins clogged with foreign matter Lack of coolant or oil Install correct shroud. Clean (wash with water), check, or repair condenser fins. Add to specified level. Adjust to specification.

Pressure of high-pressure side is too high (above Engine approx. 2 MPa {20 kg/cm2}).

Engine tends to overheat.

Incorrect fuel injection timing

Defective water pump or poor Repair or replace. capacity Radiator fins clogged with forClean fins (wash with water). eign matter Correct amount of refrigerant

Refrigeration cycle

Bubbles cannot be seen through the sight Excessive refrigerant glass when condenser is cooled with water Pressure drops approx.

0.2 MPa {2 kg/cm2} Air in refrigerant cycle immediately after compressor turns off. Abnormally high outside air Others Excessive thermal load temperature Clogging of expansion valve (defective adjustment, entry of foreign matter) Expansion valve is not Gas leak at temperature sensPressure of wet with dew, and ing bulb low-pressure side low-pressure piping is is too low (below Expansion valve not cold. Expansion valve temporarily approx. 0.05 MPa clogged due to icing (problem caused by water in circuit) {0.5 kg/cm2}).

Change refrigerant (thoroughly evacuate the system). Enhance cooling of condenser. Replace expansion valve. Replace expansion valve. Replace expansion valve, receiver tank, and drier, and then thoroughly evacuate the system.

Clogging of expansion valve Expansion valve frosted (defective adjustment, entry of Replace expansion valve. foreign matter)

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".

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80-41

Air conditioner Checking of refrigeration cycle

No.

Symptom

Location

Condition Poor cooling, and continuous flow of bubbles can be seen through sight glass Receiver tank and drier is abnormally cold (ex. frosted). Output air temperature is low, and air is not delivered. Insufficient thermal load Pressure of high- and low-pressure sides become the same as soon as compressor turns off.

Probable cause Lack of refrigerant Leakage of gas Clogging of receiver tank, or drier (Entry of foreign material) Evaporator is frosted. Abnormally low outside air temperature Defective compression at compressor

Remedy Add to specified level. Check and repair gas leakage. Replace receiver tank or drier (thoroughly evacuate the system). Check and adjust amplifier and thermistor.

Refrigeration Pressure of cycle low-pressure side is too low (below approx. 0.05 MPa {0.5 kg/cm2}). Others

Compressor

Replace compressor.

Pressure of high-pressure side Expansion valve is not is too low (below wet with dew, and Expansion valve approx. 1 MPa low-pressure piping is not cold. {10 kg/cm2}).

Clogging of expansion valve (defective adjustment, entry of Replace expansion valve. foreign matter) Gas leak at temperature sensReplace expansion valve. ing bulb Replace expansion valve, Expansion valve temporarily receiver tank, and drier, and clogged due to icing (problem then thoroughly evacuate the caused by water in circuit) system. Lack of refrigerant Add to specified level.

Refrigeration cycle Compressor Leakage of gas or Refrigeration oil cycle

Poor cooling, and continuous flow of bubbles can be seen through sight glass. Shaft seals are oily and gas level goes down. Piping joints are oily and gas level goes down. Magnet clutch does not engage even when air conditioner switch is ON..

Gas leakage from shaft seals

Replace compressor.

Gas leakage from piping con- Retighten piping connection or nection replace piping. Open circuit in coil Replace

Magnet clutch does Clutch body not engage.

Wire breakage, defective wiring, or defective connection of Connect, repair, or replace wiring parts (grounding, fuses, parts that have open circuits. etc.) Defective contact or malfuncRepair or replace. tion of switch

Magnet clutch engages if pressing it so that Excessive gap between rotor rotor moves slightly as and stator soon as air conditioner switch is turned to ON. Slipping magnet clutch
k

Repair or replace.

Clutch body

Dropped battery voltage Charge battery. Clutch slips during rotaClutch surface is dirty with oil. Remove oil. tion. Layer short in coil Replace

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

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Air conditioner Checking of refrigeration cycle

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 procedure.

1. Gas leak detector 2. Suction probe 1) Performing preliminary check 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 manifold, 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 ventilated 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 connection can be carried away by a slight movement or air. When bringing the end of suction probe (2) close to the suspected area, check in all directions from the area.

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 used, not only because R134a does not contain chlorine, but also it will decompose R134a into harmful substances.

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80-43

Air conditioner Checking of refrigeration cycle

2) Checking procedure of gas leakage

80-44

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Air conditioner Checking of refrigeration cycle

[Reference] q Checking gas leakage by pressurizing with air This checking procedure can be applied to 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 or higher. q If the gauge reading is approx. 0.2 to 0.4 MPa {2 to 4 kg/cm2}, proceed with the check. q If the gauge reading is below approx. 0.2 MPa {2 kg/cm2}, add refrigerant until the pressure becomes approx. 0.4 MPa {{4 kg/cm2} or higher, and then proceed with the check. b. Check for gas leaks by using a gas leak detector. a When the gas leakage check is complete, replace the refrigerant with new refrigerant if air is mixed in the gas.

?Pressurizing with air) 1] Connect the air compressor by using gauge manifold (3), air attachment (1), and plug (2).

2] Start the air compressor and send air to the air conditioner piping to pressurize the refrigeration cycle. a Air pressure: 1.0 MPa {10 kg/cm2} 3] After the refrigeration cycle is pressurized, set the valve dial on the gauge manifold to "Closed" in order to maintain pressure in the air conditioner piping. a Be sure to drain water from the air compressor used for pressurizing. Water will hardly enter the refrigeration cycle if this work is performed. a Limit the charging air pressure to 1.0 MPa {10 kg/cm2} or below. k Ask a qualified shop for collecting, adding, and filling operation of refrigerant (R134a). For details, see "Precautions for refrigerant".

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80-45

Air conditioner Troubleshooting for unusual noise

Troubleshooting for unusual noise

1. Unusual noise may be generated in various operating conditions, so ask the following questions for troubleshooting. q Is the unusual noise heard when the air conditioner is off? q Is the unusual noise heard only when the air conditioner is on? q Is the unusual noise heard sometimes, continuously, or immediately after the air conditioner 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 V-belt Magnetic clutch Blower motor Unusual noise Compressor
q q q q q q q q q q

80-46
2. General causes and sources of unusual noise are shown below.

Cause Looseness Worn or broken bearing Interference between stator and rotor Foreign material caught in Insufficient tightening of blower Loosened bracket mounting bolt Defects related to valves Worn or broken bearing Misalignment Poorly tightened or improperly installed clamps and fasteners Improper safety gaps

Piping
q

[Reference] q Checking sources of unusual noise Using stethoscope (1) is one of the recommended methods to locate the source of unusual noise. <Example> For example, unusual noise from compressor (2) can be located as follows. q If the noise is heard from around compressor (2), it is necessary to determine whether the noise is generated from loose bracket mounting 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.

2] Place stethoscope (1) on compressor (2) and listen to check whether the same noise is heard from the inside. If the same noise is heard, compressor (2) may be defective. a Generally, unusual noise from the compressor can be heard regardless of the engine speed.

80-46

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Air conditioner Electrical system

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 defective 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.

80-47

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80-47

Air conditioner Electrical system

2. Electrical circuit diagram

80-48

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Air conditioner Parts replacement

Parts replacement
1. Precautions for disconnecting refrigerant cycle piping k Collect the refrigerant (air conditioner gas: R134a) from air conditioner circuit before disconnecting air conditioner piping to remove or replace the 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 atmosphere. k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. Accordingly, put on protective eyeglasses, safety gloves and long sleeved work clothes when collecting or charging with the refrigerant. 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 systems 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 diameters. Since parts such as compressor oils and O-rings cannot be easily distinguished by the appearance, strictly classify the parts into R134a system parts and R12 system parts for storage and use.

80-49
3. Connection of piping 1) Precautions for connection q When removing O-rings, use a soft tool to avoid damaging the piping. q When the piping or cycle parts were replaced, be sure to replace the O-rings with new ones for R134a. q When connecting the piping, apply compressor oil (ND-OIL8) to O-rings and tighten to the specified torque. a Do not apply oil to the threaded portion of a bolt, nut, or union. a Do not use mineral lubrication oils such as SUNISO, CRC, etc.

Use two wrenches for secure connection. a Hold the device side with one wrench and turn the flare nut of the hose with another wrench.

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80-49

Air conditioner Parts replacement

2) Tightening torque of piping connection

Connection Hose size Tube size f8 Nut type D1/2 D5/8 Block joint Thread size (width across flats) (mm) M16x1.5 (19) M22x1.5 (24) M24x1.5 (27) Receiver tank portion M6x1.0 Other than receiver tank M6x1.0 Tightening torque (Nm {kgcm}) 1215 {118147} 2025 {196245} 3035 {294343} 4.07.0 {3969} 8.012.0 {78118} Used at COND1 OUT COND2 OUT REC TO UNIT IN COND1 IN COND2 IN UNIT OUT RECEIVER TANK COMPRESSOR A/C UNIT A B C

1. Compressor 2. Condenser unit 3. Receiver drier 4. Air conditioner unit

80-50

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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 Refill capacity of compressor oil (reference) Compressor oil 80 cc Condenser 40 cc Evaporator 40 cc ND-OIL8 Receiver tank 10 cc Piping 10 cc (per container)

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 easily absorb water, shut the container immediately after use.

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80-51

Air conditioner Periodic inspection and maintenance

Periodic inspection and maintenance

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 items Refrigerant (gas) (sight glass) Condenser Compressor Air filter (for FRESH/RECIRC air) Belt Blower motor Control mechanism Mounts and piping Refill capacity Clogged fins Operating condition Clogging Damage and tension Operating condition and unusual noise Operating condition Installation condition, looseness at tightening or connecting portions, leakage of gas, and damage q q(Every three months) q q q q q Inspection and maintenance interval Every six months q q Every 12 months q q q

80-52

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 danger. 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 adequate distance when using pressured water. a For details, see Operation and Maintenance Manual, "Inspection and maintenance, when required".

80-52

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Air conditioner Periodic inspection and maintenance

2) Cleaning air conditioner fresh air filter element k When using compressed air, put on protective glasses, dust mask and other protective gears since dirt will scatter and it can cause injury. q Turn off the air conditioner before cleaning the element. 1] Open air conditioner fresh air filter cover (1) at the rear of the cab. 2] Remove wing bolt (2), and then remove and clean filter element (3). 3] Blow dry compressed air (Max. 0.2 MPa {2 kg/cm2}) along the inside pleats of the element. Next, blow air along the outside pleats, and blow again along the inside pleats. a When reinstalling the outer element, install it with the arrow on the top of the element facing the inside of the cab. a For details, see Operation and Maintenance Manual, "Inspection and maintenance, every 100 hours".

3) Cleaning air conditioner recirculation air filter element 1] Open filter inspection covers (1) and (2), and remove filter cover (3). 2] Pull out filter (4) in the direction of the arrow. a To pull out the lateral filter, put your weight on the seat to press down. 3] Clean the filter by using compressed air in the same way as cleaning the fresh air filter. For details, see "Cleaning of air conditioner fresh air cleaner". a If the filter is severely contaminated, rinse it with water. Dry the rinsed filter thoroughly before reinstalling it. a For details, see Operation and Maintenance Manual, "Inspection and maintenance, every 250 hours".

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Air conditioner Periodic inspection and maintenance

2. Checking of refrigerant volume (through sight glass) 1) Satisfy the following conditions. q Door: fully opened q Temperature control: max cool q Blower speed: HI q FRESH/RECIRC air changeover: RECIRC 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 seen. : Pressure of both high- and low-pressure sides is high. Cooling will be insufficient. q Insufficient refrigerant: Continuous flow of bubbles can be seen.

3. Checking of functional parts 1) Checking the control mechanism Operate the switches on control panel (1) to check if they work smoothly and positively. If any abnormality is found, check, adjust, or repair the abnormal part.

2) Checking belts Check belt (1) for damage. If damaged, replace it with a new one. Also, check if the belt tension is within the standard value range. If out of the standard value range, adjust the belt tension. a For details, see "Testing and adjusting compressor belt tension".

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Air conditioner Periodic inspection and maintenance

3) Checking of compressor and magnet clutch Turn on the air conditioner switch to check if magnet clutch (1) engages. Also, check if any unusual noise is heard from magnet clutch (1) or the compressor. If unusual noise is heard, adjust or repair the component.

5) Cleaning condenser If a large amount of mud or dirt adheres to fins of condenser (1), cooling will be insufficient. Wash them off with water. a If heavily adhered, use a soft hair brush for washing.

4) Checking idler pulley Check if any unusual noise is heard from idler pulley (1). If unusual noise is heard, repair the pulley.

6) Checking of installation Check the installed condition of each part (loosening of mounting bolts, nuts, screws). If any part is loosened, retighten it. 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".

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80-55

Air conditioner Testing and adjusting compressor belt tension

Testing and adjusting compressor belt tension

Checking 80-56 a Check belt (1) for damage. If damaged, replace it with a new one. 80-56 Adjust a Press the middle point between compressor pulley (2) and drive pulley (3) with a finger and make adjustment so that deflection of belt (1) becomes (a). q Deflection when pressed with force of approximately 98.1 N {10 kg} (a): 9.012.5 mm

80-56

80-56

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SEN0547533-00

90-1

WA1200-6

WHEEL LOADER WA1200-6

Shop Manual

9-01

Machine model
WA1200-6

Serial number
60001 and up

90 Diagrams and drawings

90-1

WA1200-6

90-1

Contents

Contents
90 Diagrams and drawings Hydraulic circuit diagram......................................................................................................... Circuit symbols used in hydraulic circuit diagrams .............................................................. Transmission hydraulic circuit diagram................................................................................ Brake hydraulic circuit diagram............................................................................................ Work equipment hydraulic circuit diagram ........................................................................... Electrical circuit diagram ......................................................................................................... Circuit symbols used in electrical circuit diagrams............................................................... Electrical circuit diagram ...................................................................................................... 90909090909090903 3 6 8 11 15 15 19

90-2

90-2

WA1200-6

Hydraulic circuit diagram Circuit symbols used in hydraulic circuit diagrams

Hydraulic circuit diagram

Circuit symbols used in hydraulic circuit diagrams

90-3
(Rev. 2010/03)

90-3

WA1200-6

90-3

Hydraulic circuit diagram Circuit symbols used in hydraulic circuit diagrams

90-4

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Hydraulic circuit diagram Circuit symbols used in hydraulic circuit diagrams

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90-5

Hydraulic circuit diagram Transmission hydraulic circuit diagram

Transmission hydraulic circuit diagram

90-6

90-6

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Hydraulic circuit diagram 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

Hydraulic circuit diagram Brake hydraulic circuit diagram

Brake hydraulic circuit diagram

90-8

90-8

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Hydraulic circuit diagram Brake hydraulic circuit diagram

WA1200-6

90-9

Hydraulic circuit diagram Brake hydraulic circuit diagram

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)

WA1200-6

Work equipment hydraulic circuit diagram (1/2) WA1200-6

WA1200-6

90-11

Work equipment hydraulic circuit diagram (2/2)

WA1200-6

Work equipment hydraulic circuit diagram (2/2) WA1200-6

WA1200-6

90-13

Electrical circuit diagram Circuit symbols used in electrical circuit diagrams

Electrical circuit diagram

Circuit symbols used in electrical circuit diagrams

90-15
(Rev. 2010/03)

90-15

WA1200-6

90-15

Electrical circuit diagram Circuit symbols used in electrical circuit diagrams

90-16

WA1200-6

Electrical circuit diagram Circuit symbols used in electrical circuit diagrams

WA1200-6

90-17

Electrical circuit diagram Circuit symbols used in electrical circuit diagrams

90-18

WA1200-6

Electrical circuit diagram (1/13)

WA1200-6

Electrical circuit diagram (1/13) WA1200-6

WA1200-6

90-19

Electrical circuit diagram (2/13)

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Electrical circuit diagram (2/13) WA1200-6

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90-21

Electrical circuit diagram (3/13)

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Electrical circuit diagram (3/13) WA1200-6

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90-23

Electrical circuit diagram (4/13)

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Electrical circuit diagram (4/13) WA1200-6

WA1200-6

90-25

Electrical circuit diagram (5/13)

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Electrical circuit diagram (5/13) WA1200-6

WA1200-6

90-27

Electrical circuit diagram (6/13)

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Electrical circuit diagram (6/13) WA1200-6

WA1200-6

90-29

Electrical circuit diagram (7/13)

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Electrical circuit diagram (7/13) WA1200-6

WA1200-6

90-31

Electrical circuit diagram (8/13)

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Electrical circuit diagram (8/13) WA1200-6

WA1200-6

90-33

Electrical circuit diagram (9/13)

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Electrical circuit diagram (9/13) WA1200-6

WA1200-6

90-35

Electrical circuit diagram (10/13)

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Electrical circuit diagram (10/13) WA1200-6

WA1200-6

90-37

Electrical circuit diagram (11/13)

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Electrical circuit diagram (11/13) WA1200-6

WA1200-6

90-39

Electrical circuit diagram (12/13)

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Electrical circuit diagram (12/13) WA1200-6

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90-41

Electrical circuit diagram (13/13)

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Electrical circuit diagram (13/13) WA1200-6

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90-43

Index

Index
A
Accumulator (for brake) 10-119 Accumulator (for EPC valve) 10-180 Adjusting AJSS lever angle sensor and frame angle sensor 30-133 Adjusting lift arm levelness detecting switch 30-130 Adjusting lift arm potentiometer 30-129 Adjusting speed sensor 30-24 Adjusting steering follow-up linkage 30-45 Adjustment method of auto grease injector delivery 30-125 Air conditioner components 80-12 AJSS 10-68 Axle 10-61 Axle mount 10-129, 60-54

D
Damper 10-4, 60-7 Differential 60-32 Disassembly and assembly of center support 50-253 Disassembly and assembly of damper 50-91 Disassembly and assembly of differential 50-225 Disassembly and assembly of drive shaft 50-203 Disassembly and assembly of final drive and brake 50-238 Disassembly and assembly of MESABI oil cooler 50-105 Disassembly and assembly of modulation clutch 50-142 Disassembly and assembly of operator seat 50-406 Disassembly and assembly of parking brake 50-194 Disassembly and assembly of PTO and transfer 50-146 Disassembly and assembly of torque converter 50-131 Disassembly and assembly of transfer 50-187 Disassembly and assembly of transmission assembly 50-166 Disassembly and assembly of work equipment cylinder 50-329 Disassembly and assembly procedures for MESABI oil cooler 50-102 Disconnection and connection of torque converter assembly, PTO and transfer assembly 50-127 Disconnection and connection of transmission assembly and torque converter assembly 50-120 Disconnection and connection of transmission assembly, transfer, and parking brake assembly 50-159 Diverter valve 10-103, 60-43

B
Basic checks 80-32 Basic precautions for KOMTRAX Plus controller 30-138 Before performing troubleshooting of steering oil pressure system (how to use the multi monitor) 40-595 Before performing troubleshooting of work equipment hydraulic system (how to use the multi monitor) 40-518 Bleeding air from brake circuit 50-66 Bleeding air from hydraulic circuit 30-117 Bleeding air from piston pump 50-68 Bleeding air from steering circuit 30-42 Bleeding air from work equipment circuit and steering circuit 50-69 Brake 10-122, 60-51 Brake equipment layout drawing 10-108 Brake hydraulic circuit diagram 90-8 Brake oil pressure group 40-651 Brake oil pressure system, general 40-650 Brake valve 10-109, 60-48 Breakage of hydraulic cylinder 40-24 Bucket positioner, remote positioner 60-74

E
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 ECMV 10-29, 60-17 Electric fan and condenser 80-20 Electric parking brake control 10-347 Electrical circuit diagram 90-19 Electrical system 80-48 Emergency parking brake release valve 10-125 Emergency steering pump 60-47 Emergency steering relief valve 10-106 Engine mount 60-3 Engine starting circuit 10-341 Engine stopping circuit 10-343 EPC valve (for steering) 10-102 EPC valve (for work equipment) 10-175 equipment is low) 30-107

C
Center hinge pin 10-131, 60-56 Center support 10-60, 60-30 Charge valve 10-115 Check before troubleshooting 40-10 Check valve of parking brake circuit 10-126 Checking center hinge pin lubrication 30-123 Checking of refrigeration cycle 80-39 Checking proximity switch operation pilot lamp 30-132 Checking steering related standard values 40-608 Circuit symbols used in electrical circuit diagrams 90-15 Circuit symbols used in hydraulic circuit diagrams 90-3 Classification and procedures of troubleshooting 40-21 Coating materials list 50-6 Compressor 80-19 Configuration and function of refrigeration cycle 80-4 Connector list and layout 40-84 Control system 80-8 Conversion table 00-54 Cooling fan motor 10-6 Cooling fan motor 60-5 Cooling system 10-5, 60-4

WA1200-6

Index

Explanation of terms for maintenance standard

00-23

F
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 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

WA1200-6

Index

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 [DBB7KP] VHMS 12 V source sys Error 40-242 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 Malfunction40-260 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 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

WA1200-6

Index

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 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 [DW5PKA] Boom EPC solenoid (raise2) disconnection 40-425 Failure code [DW5PKB] Boom Raise EPC solenoid (2) ground fault 40-426 Failure code [DW5PKY] Boom Raise EPC solenoid (2) hot short 40-427 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 [DW5SKA] Bucket dump2 EPC solenoid disconnection 40-434 Failure code [DW5SKB] Bucket dump2 EPC solenoid short circuit 40-435

WA1200-6

Index

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 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 Failure codes table 40-27 Final drive 10-66, 60-36 Flushing procedure for brake circuit 50-54 Flushing procedure for torque converter and transmission circuit 30-32 Flushing procedure for work equipment and steering circuit 50-60

H
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 Handling of electric equipment 00-30 Handling of hydraulic components 00-25 How to measure play of center hinge bearing 30-36 How to read Disassembly and Assembly 50-4 How to read electric wire code 00-40 How to read the shop manual 00-21 Hydraulic piping drawing of torque converter and transmission 10-13 Hydraulic piping layout drawing 10-133 Hydraulic tank 10-136

I
Information contained in troubleshooting table (H mode) 40-701 Information in troubleshooting table 40-44 Initial setting procedure for KOMTRAX Plus controller 30-148 Initial setting procedure for remote boom positioner (origin input method) 30-131 Inspection and maintenance of KOMTRAX Plus controller 30-147

WA1200-6

Index

Interview and confirmation of failure symptom

80-31

R
Receiver drier 80-22 Releasing remaining pressure in hydraulic circuit 30-122 Relief valve 10-179 Removal and installation of air conditioner unit assembly 50-404 Removal and installation of air-cooled torque converter and transmission, and brake oil cooler assembly 50- 86 Removal and installation of brake accumulator charge valve assembly 50-265 Removal and installation of brake oil tank assembly 50-266 Removal and installation of bucket cylinder assembly 50-304 Removal and installation of bulkhead assembly 50-396 Removal and installation of bumper and fuel tank assembly 50-98 Removal and installation of center hinge pin 50-268 Removal and installation of center support assembly 50-251 Removal and installation of controller assembly 50-443 Removal and installation of damper assembly 50-89 Removal and installation of differential assembly 50-223 Removal and installation of DT connector pin 50-439 Removal and installation of emergency diverter valve assembly 50-262 Removal and installation of emergency steering pump assembly 50-264 Removal and installation of engine assembly 50-79 Removal and installation of front axle assembly 50-205 Removal and installation of front final drive assembly 50-207 Removal and installation of HD connector pin 50-441 Removal and installation of hood assembly 50-100 Removal and installation of hydraulic tank, filter case assembly 50-284 Removal and installation of lift cylinder assembly 50-315 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 operator's cab and floor assembly 50-398 Removal and installation of operator's cab assembly 50-402 Removal and installation of parking brake assembly (installed on the machine) 50-197 Removal and installation of radiator and hydraulic oil cooler assembly 50-72 Removal and installation of rear axle assembly 50-209 Removal and installation of rear final drive assembly 50-220 Removal and installation of steering cylinder assembly 50-258 Removal and installation of steering demand valve assembly 50-257 Removal and installation of steering pump, control pump and PPC pump assembly 50-202 Removal and installation of switch pump assembly 50-289 Removal and installation of torque converter and transmission assembly 50-113

J
Jack-up point 10-132

L
Layout drawing of connector pins List of abbreviation Lubrication relief valve 40-48 00-50 60-23

M
Machine monitor system 10-196 Main relief valve and torque converter relief valve 10-24 Main relief valve, torque converter relief valve 60-14 Measurement procedure by downloading data in KOMTRAX Plus controller 30-173 Measurement procedure by multi monitor 30-177 Measuring engine oil pressure 30-17 Measuring exhaust gas temperature 30-18 Measuring point of hydraulic pump oil pressure 30-91 Measuring wear of rear axle support 30-38 Measuring wind speed across radiator and oil cooler 30-21 Mesuring wear of wheel brake disc 30-61 Method of disconnecting and connecting push-pull type coupler 00-27 Method of releasing parking brake manually 30-78 Multi-function monitor 10-224

N
Neutral cutoff solenoid valve (NC valve) nitrogen gas No.1 work equipment pump No.2 work equipment pump 10-177 30-80 60-59 60-62

O
Operation test of work equipment valve by work equipment speed (speed of work equipment is low) 30-107 Outline of measurement procedure for Pm Clinic 30-236 Outline of refrigeration cycle 80-6

P
Parking brake 10-123, 60-52 Parking brake solenoid valve 10-124 Parts replacement 80-50 Periodic inspection and maintenance 80-53 Pm clinic service 30-238 Power train 10-11 PPC relief valve 60-65 Precautions for refrigerant 80-3 Precautions for replacing KOMTRAX Plus controller 30-165 Precautions when performing work 00-43 Preparation for measurement for Pm Clinic 30-237 Procedure for disconnecting front frame and rear frame 50-267 Procedure for running in bucket pin 50-391 Procedure for running in lift arm pin 50-393 Procedure for testing diodes 30-137 Pump control relief valve 60-66

WA1200-6

Index

Removal and installation of transmission, brake cooling device and brake pump assembly 50-201 Removal and installation of water-cooled torque converter and transmission oil cooler assembly 50-88 Removal and installation of work equipment assembly 50-335 Removal and installation of work equipment control valve assembly 50-290 Repairing HD connector pin harness 50-442 Retrieval of disabled machine due to transmission valve failure 30-33 Rotary valve 10-99

S
Safety notice 00-16 Safety precautions to follow before starting work 30-9 Sensor 10-357 Sequence of events in troubleshooting 40-9 Service tools 80-23 Setting method of auto grease timer 30-126 Sketches of special tools 50-14 Slack adjuster 10-120, 60-50 Special functions of multi monitor 30-179 Special tool list 50-9 Specification dimension drawing 01-3 Specifications 01-4 Standard tightening torque table 00-46 Standard value table for chassis 20-4 Standard value table for engine 20-3 Steering cylinder 60-45 Steering cylinder mount 60-44 Steering demand valve 10-89, 60-41 Steering equipment layout drawing 10-67 Steering lock valve 10-107 Steering oil pressure group 40-610 Steering oil pressure system, general 40-609 Steering pump 10-70, 60-38 Switch pump 10-72, 60-39 Symptom and troubleshooting numbers 40-8, 40-43

T
T- branch box and T- branch adapter table 40-104 Table of fuel, coolant and lubricants 01-9 Table of fuse locations 40-107 Testing accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 30-80 Testing additional cooler fan speed 30-31 Testing and adjusting accumulator charge pressure 30-62 Testing and adjusting air conditioner compressor belt tension 30-23 Testing and adjusting bucket proximity switch 30-128 Testing and adjusting compressor belt tension 80-57 Testing and adjusting differential valve output oil pressure 30-97 Testing and adjusting emergency steering oil pressure 30-40 Testing and adjusting fan belt tension 30-22 Testing and adjusting potentiometer mounting position 30-134 Testing and adjusting PV control relief valve oil pressure 30-95 WA1200-6

Testing and adjusting steering main relief valve oil pressure 30-54 Testing and adjusting steering oil pressure 30-39 Testing and adjusting steering stopper bolt 30-44 Testing and adjusting steering surge cut valve oil pressure 30-52 Testing and adjusting torque converter and transmission oil pressure 30-26 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 Testing and adjusting work equipment pump TVC valve oil pressure 30-105 Testing and adjusting work pump CO (cut-off) valve oil pressure 30-101 Testing blow-by pressure 30-16 Testing brake accumulator oil pressure leakage 30-64 Testing brake cooling oil pressure 30-74 Testing brake oil cooler performance 30-76 Testing brake performance 30-58 Testing brake valve oil leakage amount 30-69 Testing emergency parking brake valve oil leakage amount 30-66 Testing engine speed 30-13 Testing exhaust gas color 30-15 Testing hydraulic oil cooler performance 30-114 Testing intake air pressure (boost pressure) 30-19 Testing lowering of wheel brake oil pressure 30-59 Testing of slack adjuster 30-60 Testing parking brake oil pressure 30-79 Testing parking brake performance 30-76 Testing radiator performance 30-20 Testing rotary valve output pressure 30-56 Testing steering EPC valve 30-50 Testing torque converter oil cooler performance 30-30 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 Torque converter 10-15, 60-10 Torque converter oil cooler 10-59 Torque converter pump, transmission pump, brake cooling pump, brake pump 60-26 Torque converter regulator valve 10-27, 60-16 Traction control function checking procedure 30-29 Transfer 10-57, 60-24 Transmission 10-35, 60-18 Transmission control system 10-315 Transmission control valve 10-46, 60-20 Transmission hydraulic circuit diagram 90-6 Transmission lubricating oil relief valve 10-56 Transmission mount 60-8 Troubleshooting 80-33 Troubleshooting for unusual noise 80-47 Troubleshooting method for open circuit in wiring harness of pressure sensor system 40-46 Troubleshooting procedures 80-30

W
Weight table Work equipment and AJSS control system 01-7 10-277

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 Work equipment oil pressure group 40-530 Work equipment pump No.1 10-139 Work equipment pump No.2 10-152

WA1200-6

DRAFT

Shop Manual

DRAFT

WA1200-6 WHEEL LOADER Form No. SEN05475-01

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