Komatsu WA1200-3 - Service Manual / Repair Manual - Wiring Diagrams

KOMATSU WA1200-3 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for Komatsu WA1200-3.
 

CONTENTS:

01 GENERAL
- General assembly drawing
- Specifications
- Weight table
- List of lubricant and water
10 STRUCTURE AND FUNCTION
- Outline
- Tadiator and hydraulic oil cooler
- Damper
- Torque converter and transmission piping
- Torque converter
- Main relief valve and torque converter relief valve
- Torque converter regulator valve
- Ecmv
- Transmission
- Transmission control valve
- Lubricating oil relief valve
- Transfer
- Torque converter oil cooler
- Center support
- Axle
- Final drive
- Axle mount
- Center hinge pin
- Jack-up point
- Arrangement of steering equipment
- Ajss (advanced joystick steering system)
- Steering pump
- Switch pump
- Servo valve
- Steering demand valve
- Rotary valve
- Epc valve
- Diverter valve
- Arrangement of brake equipment
- Brake valve
- Harge valve
- Accumulator (for brake)
- Slack adjuster
- Brake
- Parking brake
- Parking brake oil circuit check valve assembly
- Arrangement of hydraulic equipment
- Work equipment lever linkage
- Hydraulic tank
- Work equipment pump no.1
- Work equipment pump no.2
- Work equipment pump neutral cut valve (nc valve)
- Ppc valve (proportional pressure valve)
- Ppc relief valve
- Accumulator(for ppc valve)
- Main control valve
- Work equipment linkage
- Operation of proximity switch
- Air conditioner
- Machine monitor system
- Main monitor
- Cgc monitor
- Multi monitor
- All-range electronic control automatic transmission (atm) system
- Modulated clutch (mod/c) control system
- Work equipment and joystick steering control system
- Work equipment and joystick steering controller
- Engine starting circuit
- Engine stopping circuit
- Ether injection circuit
- Electric parking brake control
- Parking brake solenoid valve
- Emergency parking brake reset solenoid valve
- Kick-down switch and auto shift/manual shift selector switch
- Battery disconnector switch
- Emergency engine stop switch (for rio tinto)
- Hydraulic oil level caution display (for rio tinto)
20 TESTING AND ADJUSTING
- Standard value table
- Standard Value Table For Engine
- Standard Value Table For Chassis
- Standard Value Table For Electrical Parts
- Testing and adjusting
- Items To Be Prepared List Of Devices For Troubleshooting
- Safety Precautions Before Starting Work
- Items Related To Engine Measuring Engine Speed
- Measuring Exhaust Gas Color
- Measuring Blow-By Pressure
- Measuring Engine Oil Pressure
- Measuring Exhaust Temperature
- Measuring Boostp Ressure
- Performance Check Of Radiator
- Measuring Wind Velocity Through Radiator And Oil Cooler
- Testing And Adjusting Fan Belt Tension
- Testing And Adjusting Belt Tension Of Air Conditioner Compressor
- Adjusting Rotation Sensor
- Power Train Testing And Adjusting Torque Converter And Transmission Oil Pressure
- Traction Control Function Check Procedure
- Performance Check Of Torque Converter Oil Cooler
- Measuring Fan Speed For Additional Cooler
- Flushing Procedure For Hydraulic Circuit Of Torque Converter And Transmission
- How To Move Machine When Transmission Valve Is Broken
- How To Measure Clearance (Play) In Center Hinge Bearing
- Measurement Procedure For 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
- 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
- Measuring Rotary Valve Output Pressure
- Brake System Testing Drop Of Wheel Brake Oil Pressure
- Testing Wheel Brake Function
- Checking Slack Adjuster
- Measuring Wear Of Wheel Brake Disc
- Testing And Adjusting Charge Cut-In And Cut-Out Pressure Of Accumulator
- Testing Brake Accumulator For Leakage
- Testing Emergency Parking Brake Valve For Oil Leakage
- Testing Brake Valve For Oil Leakage
- Testing Brake Cooling Oil Pressure
- Performance Check Of Brake Oil Cooler
- Testing Parking Brake Performance
- Testing Wear Of Parking Brake Disc
- How To Reset Parking Brake Manually
- Measuring Parking Brake Oil Pressure
- Hydraulic Equipment Testing And Adjusting Work Equipment Oil Pressure
- Measurement Procedure Of Work Equipment Oil Pressure With Oil Pressure Gauge
- Testing And Adjusting Ppc Oil Pressure
- Adjusting Ppc Valve Linkage
- Measuring Points Of Hydraulic Pump Oil Pressure
- Hydraulic Pump Piping Line
- Testing And Adjusting Pv Control Relief Valve Oil Pressure
- Testing And Adjusting Differential Pressure Valve Control Oil Pressure
- Testing Work Equipment Pump Es Valve Output Pressure
- Testing And Adjusting Work Equipment Pump Co Valve (Cut-Off) Oil Pressure
- Testing Work Equipment Control Valve Operation By Work Equipment Speed (Work Equipment Speed Is Low)
- Performance Check Of Hydraulic Oil Cooler (Check By Temperaturedifference)
- Performance Check Of Hydraulic Oil Cooler (Check By Measuring Oil Pressure)
- Bleeding Air From Each Part
- Releasing Residual Pressure From Hydraulic Circuit
- Testing Of Accumulator Nitrogen Gas Pressure And Procedure For Charging Accumulator With Nitrogen Gas
- Work Equipment System Checking And Adjusting Work Equipment Control Lever Linkage
- Electrical Equipment Testing And Adjusting Bucket Proximity Switch
- Testing And Adjusting Lift Arm Potentiometer
- Adjusting Lift Arm Horizontal Detection Switch
- Procedure For Setting Initial Value For Remote Lift Arm Positioner (Method Of Inputting Base Point)
- Checking Proximity Switch Actuation Pilot Lamp
- Initial Learning Method Of Transmission Controller
- Adjusting Main Monitor (Speedometer Module)
- Adjusting Steering Lever Angle And Frame Angle Sensors
- Checking And Adjusting Installed Positions Of Potentiometers
- Procedure For Checking Diode
- Checking Greasing Condition Of Center Hinge Pin Portion
- Method Of Adjusting Auto-Grease Injector Discharge Amount
- Method Of Setting Auto-Grease Timer
- Vhms Controller Basic Precautions
- Testing And Maintaining Vhms Controller
- Vhms Controller Initial Setting Procedure
- Precautions For Replacing Vhms Controller
- Measurement Procedure By Downloading Data In Vhms Controller
- Measurement Procedure By Cgc Monitor
- Measurement Procedure By Multi Monitor
- Special Functions Of Machine Control Monitor (Multi Monitor)
- Outline Of Measurement Procedure For Pm Clinic
- Preparation For Measurement For Pm Clinic
- Pm Clinic Check Sheet
- Troubleshooting
- Points To Remember When Troubleshooting
- Sequence Of Events In Troubleshooting
- Checks Before Troubleshooting
- Troubleshooting Procedure For Work Equipment Hydraulic System And Steering System
- Handling Of Electric Equipment And Hydraulic Component
- Connector Types And Mounting Locations
- Connector Arrangement Diagram
- Connection Table For Connector Pin Numbers
- T-Branch Box And T-Branch Adapter Table
- Explanation Of Functions Of Electric Control Mechanism
- Method Of Displaying Action Code And Failure Code
- Failure Codes List
- Method Of Using Judgement Table
- Method Of Using Troubleshooting Charts
- Method Of Using Matrix Troubleshooting Tables
- Troubleshooting Of Engine Controller System (G Mode)
- Troubleshooting Of Transmission Controller System (T Mode)
- Troubleshooting Of Modulated Clutch Controller System (Mc Mode)
- Troubleshooting Of Work Equipment Controller (Joystick Steering Control) System (J Mode)
- Troubleshooting Of Work Equipment Controller (Remote Boom Positioner Control) System (W Mode)
- Troubleshooting Of Main Monitor System (M Mode)
- Troubleshooting Of Vhms Controller System (V Mode)
- Troubleshooting Of Hydraulic And Mechanical System (H Mode)
- Troubleshooting By Failue Code (Display Of Code)
- Troubleshooting Of Electrical System (Without Failure Code) (E-Mode)
30 DISASSEMBLY AND ASSEMBLY
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- Procedure for flushing work equipment and steering hydraulic circuit
- Procedure for flushing brake hydraulic circuit
- Bleeding air from piston pump
- Bleeding air from work equipment circuit and steering circuit
- Bleeding air from brake circuit
- Removal and installation of dt connector pin
- Removal and installation of hd connector pin
- Repair procedure of hd connector pin harness
- Removal and installation of engine assembly
- Removal and installation of damper assembly
- Disassembly and assembly of damper assembly
- Removal and installation of radiator and hydraulic oil cooler assembly
- Procedure for disassembly and assembly of mesabi oil cooler assembly
- Disassembly and assembly of mesabi oil cooler assembly
- Removal and installation of fuel cooler assembly
- Removal and installation of torque converter and transmission oil cooler assembly
- Removal and installation of bumper and fuel tank assembly
- Removal and installation of hood assembly
- Removal and installation of bulkhead assembly
- Disassembly and assembly of ecmv
- 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 and pto • transfer assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of modulated clutch assembly
- Disassembly and assembly of pto and transfer assembly
- Disconnection and connection of transmission assembly and transfer • parking brake assembly
- Disassembly and assembly of transmission assembly
- Disassembly and assembly of transfer assembly
- Disassembly and assembly of parking brake assembly
- Removal and installation of parking brake assembly (from machine body)
- Disassembly and assembly of drive shaft assembly
- Removal and installation of front axle assembly
- Removal and installation of front final drive assembly
- Removal and installation of rear axle assembly
- Disconnection and connection of differential assembly
- Disassembly and assembly of differential assembly
- Removal and installation of rear final drive assembly
- Disassembly and assembly of final drive and brake assembly
- Removal and installation of center support assembly
- Disassembly and assembly of center support assembly
- Removal and installation of steering demand valve assembly
- Removal and installation of steering cylinder assembly
- Removal and installation of steering pump, control pump and ppc pump assembly
- Removal and installation of switching pump 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 cooler assembly
- Removal and installation of brake oil tank assembly
- Removal and installation of transmission, brake cooling and brake pump assembly
- Disconnecting procedure for front frame and rear frame
- Removal and installation of center hinge pin
- Removal and installation of work equipment control valve assembly
- Removal and installation of work equipment pump assembly (right side)
- Removal and installation of work equipment pump assembly (left side)
- Removal and installation of hydraulic tank and filter case assembly
- Removal and installation of bucket cylinder assembly
- Removal and installation of lift cylinder assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Removal and installation of work equipment assembly
- Run-in procedure for bucket pin
- Run-in procedure for lift arm pin
- Removal and installation of air conditioner unit assembly
- Removal and installation of operator's cab and floor assembly1
- Removal and installation of operator's cab assembly
- Disassembly and assembly of operator's seat assembly
- Removal and installation of controller assemblies
- Service kit parts list
40 MAINTENANCE STANDARD
- Engine mount
- Transmission mount
- Radiator and oil cooler
- Damper
- Torque converter, transmission, brake cooling and brake pump
- Input transfer. Pto
- Modulated clutch
- Torque converter
- Transmission
- Transfer
- Mainrelief, torque converter relief valve
- Torque converter regulator valve
- By-pass fill valve
- By-pass fill valve and by-pass drain valve
- Ecmv
- Lubricationg oil relief valve
- Drive shaft
- Center support
- Differential
- Final drive
- Axle mount
- Center hinge pin
- Steering pump
- Switch pump
- Steering demand valve
- Diverter valve
- Steering cylinder mount
- Emergency steering pump
- Brake valve
- Slack adjuster
- Brake
- Parding brake
- Work equipment pump no.1
- Work equipment pump no.2
- Ppc valve
- Ppc relief valve
- Pump control relief valve
- Main control valve
- Hydraulic cylinder
- Bucket positioner and remote positioner
- Bucket linkage
90 OTHERS
- Transmission hydraulic circuit diagram
- Brake circuit diagram
- Work euipment hydraulic circuit diagram (1/2) serial no. : 50001 – 50084
- Work euipment hydraulic circuit diagram (2/2) serial no. : 50001 – 50084
- Work euipment hydraulic circuit diagram (1/2) serial no. : 50085 and up
- Work euipment hydraulic circuit diagram (2/2) serial no. : 50085 and up
- Electrical circuit diagram (1/7) serial no. : 50001 – 50038 (standard specification machine)
- Electrical circuit diagram (1/7) serial no. : 50001 – 50038 (trainer seat specification machine)
- Electrical circuit diagram (2/7) serial no. : 50001 – 50038
- Electrical circuit diagram (3/7) serial no. : 50001 – 50038
- Electrical circuit diagram (4/7) serial no. : 50001 – 50038
- Electrical circuit diagram (5/7) serial no. : 50001 – 50038
- Electrical circuit diagram (6/7) serial no. : 50001 – 50038
- Electrical circuit diagram (7/7) serial no. : 50001 – 50038
- Electrical circuit diagram (1/7) serial no. : 50039 – 50074
- Electrical circuit diagram (2/7) serial no. : 50039 – 50074
- Electrical circuit diagram (3/7) serial no. : 50039 – 50074
- Electrical circuit diagram (4/7) serial no. : 50039 – 50074
- Electrical circuit diagram (5/7) serial no. : 50039 – 50074
- Electrical circuit diagram (6/7) serial no. : 50039 – 50074
- Electrical circuit diagram (7/7) serial no. : 50039 – 50074
- Electrical circuit diagram (1/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (2/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (3/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (4/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (5/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (6/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (7/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (8/8) serial no. : 50075 – 50084, 50086, 50087
- Electrical circuit diagram (1/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (2/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (3/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (4/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (5/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (6/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (7/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (8/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (9/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (10/11) serial no. : 50085, 50088 and up
- Electrical circuit diagram (11/11) serial no. : 50085, 50088 and up