Komatsu WA1200-6 Wheel Loader Service Manual

Name: Komatsu WA1200-6 Wheel Loader Service Manual
Brand: MidWestTech
SKU: SEN05475-09
Price: 209.55 USD
Availability: InStock

2,074 pages · Publication SEN05475-09

$209.55

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Models: WA1200-6
Serial coverage: 60001 and up
Manual type: Service Manual
Pages: 2,074
Publication: SEN05475-09
Condition: Brand new

Komatsu WA1200-6 Wheel Loader Service Manual, publication SEN05475-09

What's inside

From the manual's own table of contents: 10 sections, 568 entries. See sample pages (PDF, 799 KB)

Search the contents

Index and foreword12 topics

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

Specification4 topics

Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants

Structure and function67 topics

Engine and cooling system
Damper
Cooling system
Cooling fan motor
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
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

Standard value table2 topics

Standard value table for engine
Standard value table for chassis

Testing and adjusting81 topics

Tool for testing, adjusting and troubleshooting
Tools for testing, adjusting, and troubleshooting
Safety precautions to follow before starting work
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
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
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
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
nitrogen gas
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
equipment is low)
Testing hydraulic oil cooler performance
Bleeding air from hydraulic circuit
Releasing remaining pressure in hydraulic circuit
Checking center hinge pin lubrication
Adjustment method of auto grease injector delivery
Setting method of auto grease timer
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

Troubleshooting280 topics

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
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)
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)
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 [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 [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
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
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)
multi monitor)
Work equipment hydraulic system, general
Work equipment oil pressure group
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)

Disassembly and assembly72 topics

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 motor of brake and torque converter
Bleeding air from piston pump
Bleeding air from work equipment circuit and steering circuit
Removal and installation of radiator and hydraulic oil cooler assembly
Removal and installation of engine assembly
and brake oil cooler assembly
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
Removal and installation of torque converter and transmission assembly
Disassembly and assembly of torque converter
Disassembly and assembly of modulation clutch
Disassembly and assembly of PTO and transfer
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 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
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
Removal and installation of brake accumulator charge valve assembly
Removal and installation of brake oil tank assembly
Procedure for disconnecting front frame and rear frame
Removal and installation of center hinge pin
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
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
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
Removal and installation of AJSS lever switch assembly
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

Maintenance standard16 topics

Engine mount
Transmission mount
Main relief valve, torque converter relief valve
Lubrication relief valve
Torque converter pump, transmission pump, brake cooling pump, brake pump
Drive shaft
Differential
Steering cylinder mount
Steering cylinder
Emergency steering pump
No.1 work equipment pump
No.2 work equipment pump
PPC relief valve
Pump control relief valve
Bucket positioner, remote positioner
Work equipment cylinder

Appendix19 topics

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
Parts replacement
Periodic inspection and maintenance
Testing and adjusting compressor belt tension

Diagrams and drawings5 topics

Hydraulic circuit diagram
Circuit symbols used in hydraulic circuit diagrams
Transmission hydraulic circuit diagram
Brake hydraulic circuit diagram
Work equipment hydraulic circuit diagram

Inside this manual

Real pages from this service manual (2,074 pages). Open the sample pages (PDF, 798 KB)

Sample pages from the Komatsu WA1200-6 Wheel Loader Service Manual: Troubleshooting, Diagram, Specifications, Foldout diagram

Troubleshooting, page 949: Troubleshooting by failure code
Diagram, page 1,237: Troubleshooting of electrical system (E-mode),
Specifications, page 1,813: Work equipment
Foldout diagram, page 2,052: Electrical circuit diagram (1/13)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the WA1200-6 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN05475-09$209.55

Operator's manuals

Operation & Maintenance Manual TEN00511-07 · 416 pagesCovers WA1200-6Serial: 60001 and up$69.77Details

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This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 2,074 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).