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KOMATSU WA400-5 SHOP MANUAL SEBM028005 – PDF DOWNLOAD
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Description
KOMATSU WA400-5 SHOP MANUAL SEBM028005 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA400-5 SHOP MANUAL SEBM028005 – PDF DOWNLOAD
Language : English
Pages : 1158
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA400-5 SHOP MANUAL SEBM028005 – PDF DOWNLOAD
COVER................................................................................................................................................................................................ 1 CONTENTS............................................................................................................................................................................................. 2 01 GENERAL........................................................................................................................................................................................... 28 GENERAL ASSEMBLY DRAWING......................................................................................................................................................................... 29 SPECIFICATIONS................................................................................................................................................................................... 30 WEIGHT TABLE..................................................................................................................................................................................... 34 LIST OF LUBRICANT AND COOLANT.................................................................................................................................................................... 36 10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...................................................................................................................................................... 38 COOLING SYSTEM................................................................................................................................................................................... 39 ENGINE MOUNT, TRANSMISSION MOUNT................................................................................................................................................................. 40 POWER TRAIN...................................................................................................................................................................................... 41 POWER TRAIN SYSTEM DIAGRAM....................................................................................................................................................................... 42 DRIVE SHAFT (PROPELLER SHAFT).................................................................................................................................................................... 45 TORQUE CONVERTER,TRANSMISSION PIPING............................................................................................................................................................. 46 TORQUE CONVERTER................................................................................................................................................................................. 47 TRANSMISSION..................................................................................................................................................................................... 55 TRANSMISSION CONTROL VALVE....................................................................................................................................................................... 70 AXLE............................................................................................................................................................................................. 85 DIFFERENTIAL..................................................................................................................................................................................... 87 FINAL DRIVE...................................................................................................................................................................................... 98 AXLE MOUNTING,CENTER HINGE PIN................................................................................................................................................................... 104 STEERING PIPING.................................................................................................................................................................................. 108 STEERING COLUMN, ORBIT-ROLL...................................................................................................................................................................... 109 STEERING VALVE................................................................................................................................................................................... 110 ORBIT-ROLL VALVE................................................................................................................................................................................. 125 STOP VALVE....................................................................................................................................................................................... 129 STEERING PUMP, SWITCH PUMP....................................................................................................................................................................... 130 EMERGENCY STEERING PUMP (OP)..................................................................................................................................................................... 132 EMERGENCY STEERING MOTOR (OP).................................................................................................................................................................... 133 STEERING CYLINDER................................................................................................................................................................................ 134 JOYSTICK STEERING LEVER (OP)..................................................................................................................................................................... 136 STEERING LEVER (OP).............................................................................................................................................................................. 137 STEERING SWITCH VALVE (OP)....................................................................................................................................................................... 139 BRAKE PIPING..................................................................................................................................................................................... 140 BRAKE VALVE...................................................................................................................................................................................... 142 CHARGE VALVE..................................................................................................................................................................................... 149 ACCUMULATOR (FOR BRAKE).......................................................................................................................................................................... 153 BRAKE............................................................................................................................................................................................ 155 PARKING BRAKE CONTROL............................................................................................................................................................................ 160 PARKING BRAKE.................................................................................................................................................................................... 161 PARKING BRAKE SOLENOID VALVE..................................................................................................................................................................... 163 PARKING BRAKE EMERGENCY RELEASE VALVE............................................................................................................................................................ 165 HYDRAULIC PIPING................................................................................................................................................................................. 166 WORK EQUIPMENT CONTROL LEVER..................................................................................................................................................................... 169 HYDRAULIC TANK................................................................................................................................................................................... 171 TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS............................................................................................................................... 173 PPC RELIEF VALVE................................................................................................................................................................................. 175 ECSS VALVE....................................................................................................................................................................................... 177 WORK EQUIPMENT CONTROL VALVE..................................................................................................................................................................... 179 WORK EQUIPMENT PPC VALVE......................................................................................................................................................................... 196 PPC VALVE (FOR MULTI FUNCTION MONO LEVER)........................................................................................................................................................ 202 EPC SOLENOID VALVE (OP).......................................................................................................................................................................... 208 SHUT OFF VALVE (OP).............................................................................................................................................................................. 211 ATTACHMENT PPC VALVE (OP)........................................................................................................................................................................ 212 COOLING FAN MOTOR................................................................................................................................................................................ 216 COOLING FAN MOTOR DRIVE PUMP..................................................................................................................................................................... 221 WORK EQUIPMENT LINKAGE........................................................................................................................................................................... 229 BUCKET........................................................................................................................................................................................... 231 BUCKET POSITIONER, LIFT ARM KICK-OUT............................................................................................................................................................. 232 WORK EQUIPMENT CYLINDER.......................................................................................................................................................................... 238 CAB.............................................................................................................................................................................................. 239 AIR CONDITIONER (OP)............................................................................................................................................................................. 240 MACHINE MONITORING SYSTEM........................................................................................................................................................................ 241 MACHINE MONITOR.................................................................................................................................................................................. 248 TRANSMISSION CONTROL SYSTEM...................................................................................................................................................................... 309 TRANSMISSION CONTROLLER.......................................................................................................................................................................... 335 JOY STICK STEERING CONTROL SYSTEM (OP)........................................................................................................................................................... 337 WORK EQUIPMENT CONTROLLER........................................................................................................................................................................ 343 ELECTRIC TRANSMISSION CONTROL.................................................................................................................................................................... 345 KICK DOWN, HOLD SWITCH........................................................................................................................................................................... 349 ENGINE STARTING CIRCUIT.......................................................................................................................................................................... 350 ENGINE STOP CIRCUIT.............................................................................................................................................................................. 352 PREHEATING CIRCUIT............................................................................................................................................................................... 353 ENGINE POWER MODE SELECTOR CIRCUIT............................................................................................................................................................... 354 PARKING BRAKE CIRCUIT............................................................................................................................................................................ 355 SENSORS.......................................................................................................................................................................................... 359 20 TESTING AND ADJUSTING............................................................................................................................................................................. 369 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................................................................. 370 STANDARD VALUE TABLE FOR CHASSIS................................................................................................................................................................. 371 TESTING AND SDJUSTING............................................................................................................................................................................ 378 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................................................................................ 379 MEASURING ENGINE SPEED....................................................................................................................................................................... 380 MEASURING EXHAUST COLOR...................................................................................................................................................................... 382 MEASURING EXHAUST TEMPERATURE................................................................................................................................................................ 383 ADJUSTING VALVE CLEARANCE.................................................................................................................................................................... 384 MEASURING COMPRESSION PRESSURE............................................................................................................................................................... 386 MEASURING BLOW-BY PRESSURE................................................................................................................................................................... 387 MEASURING ENGINE OIL PRESSURE................................................................................................................................................................ 388 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)............................................................................................................................................... 389 TESTING AND ADJUSTING FUEL INJECTION TIMING.................................................................................................................................................. 390 ADJUSTING ENGINE SPEED SENSOR................................................................................................................................................................ 391 BLEEDING AIR FROM FUEL CIRCUIT............................................................................................................................................................... 392 ADJUSTING ENGINE STOP SOLENOID............................................................................................................................................................... 393 ADJUSTING ACCELERATOR PEDAL.................................................................................................................................................................. 394 ADJUSTING TRANSMISSION SPEED SENSOR.......................................................................................................................................................... 396 TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE............................................................................................................................................... 397 DRAWING OF SPECIAL TOOL...................................................................................................................................................................... 401 PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT...................................................................................................................... 402 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS................................................................................................................................... 403 TESTING AND ADJUSTING STEERING CONTROL....................................................................................................................................................... 405 TESTING AND ADJUSTING STEERING OIL PRESSURE.................................................................................................................................................. 406 TESTING HYDRAULIC FAN........................................................................................................................................................................ 408 MEASURING BRAKE OIL PRESSURE................................................................................................................................................................. 409 TESTING WEAR OF WHEEL BRAKE DISC............................................................................................................................................................. 411 BLEEDING AIR FROM BRAKE CIRCUIT.............................................................................................................................................................. 412 TESTING WEAR OF PARKING BRAKE DISC........................................................................................................................................................... 413 MANUAL RELEASE METHOD FOR PARKING BRAKE...................................................................................................................................................... 414 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE............................................................................................................................................ 415 TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE..................................................................................................................................... 417 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE...................................................................................................................................... 419 TESTING AND ADJUSTING BUCKET POSITIONER...................................................................................................................................................... 421 TESTING AND ADJUSTING LIFT ARM KICK-OUT...................................................................................................................................................... 422 CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP............................................................................................................................................... 423 ADJUSTING MACHINE MONITOR.................................................................................................................................................................... 424 TESTING AND ADJUSTING LOAD METER............................................................................................................................................................. 427 BLEEDING AIR................................................................................................................................................................................. 431 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................................................................ 432 RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT........................................................................................................................................ 432 PM CLINIC INSPECTION TABLE................................................................................................................................................................... 433 TROUBLESHOOTING.................................................................................................................................................................................. 435 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................................... 436 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................................................................ 437 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.................................................................................................................................................... 438 CHECKS BEFORE TROUBLESHOOTING................................................................................................................................................................ 446 EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM.............................................................................................................................................. 447 SPECIAL FUNCTIONS OF MACHINE MONITOR......................................................................................................................................................... 448 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................................ 482 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................................................................... 490 T-ADAPTER TABLE.............................................................................................................................................................................. 511 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)..................................................................................................................................... 514 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 516 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 524 TRANSMISSION CONTROL SYSTEM DIAGRAM...................................................................................................................................................... 530 ERROR CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED............................................................................................................................ 533 ERROR CODE [15SAL1] (F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED............................................................................................................. 534 ERROR CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................ 535 ERROR CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED............................................................................................................. 536 ERROR CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................................ 537 ERROR CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 538 ERROR CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 539 ERROR CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 540 ERROR CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 541 ERROR CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 542 ERROR CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 543 ERROR CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................... 544 ERROR CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED.............................................................................................................. 545 ERROR CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED........................................................................................................ 546 ERROR CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED........................................................................................................... 547 ERROR CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED....................................................................................................................... 548 ERROR CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED....................................................................................................................... 549 ERROR CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED................................................................................................... 550 ERROR CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED....................................................................................................... 551 ERROR CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED.......................................................................................................... 552 ERROR CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED.............................................................................................................. 553 ERROR CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED....................................................................................................... 554 ERROR CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED........................................................................................................... 556 ERROR CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED........................................................................................................ 558 ERROR CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED............................................................................................................ 559 ERROR CODE [D198KB] (GROUND FAULT IN LOW TEMPERATURE BYPASS RELAY SYSTEM)................................................................................................................ 560 ERROR CODE [D198KY] (HOT SHORT IN LOW-TEMPERATURE BYPASS RELAY SYSTEM) .................................................................................................................. 561 ERROR CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED............................................................................................................... 562 ERROR CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED................................................................................................................ 563 ERROR CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED....................................................................................................................... 564 ERROR CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED..................................................................................................................... 565 ERROR CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED................................................................................................................ 567 ERROR CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED................................................................................................... 569 ERROR CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED............................................................................................ 571 ERROR CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED................................................................................ 573 ERROR CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED................................................................................................................ 574 ERROR CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED........................................................................................................... 576 ERROR CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED................................................................................................................. 578 ERROR CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED..................................................................................................................... 579 ERROR CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED................................................................................................... 580 ERROR CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED................................................................................................... 582 ERROR CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED................................................................................................................ 583 ERROR CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED.................................................................................................................... 585 ERROR CODE [DF10KA] (NO INPUT OF GEAR SHIFT LEVER SIGNAL) IS DISPLAYED................................................................................................................... 586 ERROR CODE [DF10KB] (INPUT OF MULTIPLE GEAR SHIFT LEVER SIGNALS) IS DISPLAYED............................................................................................................ 588 ERROR CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED.................................................................................................... 590 ERROR CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................ 591 ERROR CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.............................................................................................. 592 ERROR CODE [DHT1KX] (TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED................................................................................ 593 ERROR CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED......................................................................................................... 594 ERROR CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED...................................................................................................................... 595 ERROR CODE [DLT3KA] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM DISCONTINUITY) IS DISPLAYED.............................................................................. 596 ERROR CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED......................................................................... 597 ERROR CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED........................................................................................................ 598 ERROR CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED..................................................................................................... 599 ERROR CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED............................................................................................................... 600 ERROR CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED................................................................................................................ 601 ERROR CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED............................................................................................................ 602 ERROR CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED............................................................................................................. 603 ERROR CODE [DXH1KA] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED..................................................................................................... 604 ERROR CODE [DXH1KB] (LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED.................................................................................................. 605 ERROR CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 606 ERROR CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 607 ERROR CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 608 ERROR CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 609 ERROR CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 610 ERROR CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 611 ERROR CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED.................................................................................................................. 612 ERROR CODE [DXH7KB] (R_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 613 ERROR CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED.................................................................................................................. 614 ERROR CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................................... 615 ERROR CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED................................................................................................................ 616 ERROR CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED............................................................................................................. 617 ERROR CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)).......................................................................................... 618 ERROR CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)).......................................................................................... 620 ACTION CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM....................................................................................................... 622 ACTION CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING.............................................................................................................. 624 ACTION CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE........................................................................................................................ 626 ACTION CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE....................................................................................................... 627 ACTION CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE.................................................................... 629 ACTION CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT ..................................................................................................... 631 ACTION CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING...................................................................................... 632 ACTION CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING...................................................................................................... 633 ACTION CODE [TM-9] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT).................................................................................... 634 ACTION CODE [TM-10-a] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE.................................................................................................................. 635 ACTION CODE [TM-10-b] STARTING SWITCH "C" (IGN_C) SIGNAL SYSTEM FAILURE.................................................................................................................. 637 ACTION CODE [TM-11] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE.................................................................................................................... 639 ACTION CODE [TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT............................................................................................................... 640 ACTION CODE [TM-13] TRAVEL DAMPER NO/OFF SWITCH DISCONTINUITY OR GROUND FAULT............................................................................................................ 641 ACTION CODE [TM-14] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY..................................................................................... 642 ACTION CODE [TM-15] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING............................................................................................. 643 ACTION CODE [TM-16] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING .............................................................................................................. 644 ACTION CODE [TM-17] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING......................................................................................................... 645 ACTION CODE [TM-18] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING................................................................................................................... 646 ACTION CODE [TM-19] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING........................................................................................................................... 647 ACTION CODE [TM-20] FECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................... 648 ACTION CODE [TM-21] RECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................... 649 ACTION CODE [TM-22] 1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 650 ACTION CODE [TM-23] 2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 651 ACTION CODE [TM-24] 3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 652 ACTION CODE [TM-25] 4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING........................................................................................................................ 653 ACTION CODE [TM-26] LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING.................................................................................................................... 654 ACTION CODE [TM-27] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING.................................................................................................................... 655 ACTION CODE [TM-28] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING..................................................................................................................... 656 ACTION CODE [TM-29] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE................................................................................................... 657 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE).................................................................................................................................. 658 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 660 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 668 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM.................................................................................................................................................... 674 ERROR CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED............................................................................... 677 ERROR CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED.................................................................................... 678 ERROR CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED....................................................................................................... 679 ERROR CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED....................................................................................................... 680 ERROR CODE [DB95KX] (DEFECTIVE 5V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED............................................................................................................. 681 ERROR CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED.............................................................................................. 683 ERROR CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED............................................................................................ 684 ERROR CODE [DFAOKM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED........................................................................................... 685 ERROR CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................ 686 ERROR CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED................................................................................ 687 ERROR CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED.................................................................... 688 ERROR CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION, GROUND OF SUB)) IS DISPLAYED.............................................. 689 ERROR CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED................................................................................. 690 ERROR CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED.......................................................... 691 ERROR CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED................................................................................ 692 ERROR CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED............................................... 693 ERROR CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................... 694 ERROR CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED................................................................................... 695 ERROR CODE [DK5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................... 696 ERROR CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED........................................................................... 697 ERROR CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED................................................ 698 ERROR CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED........................................................ 699 ERROR CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED................................................................................ 700 ERROR CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED............................................... 701 ERROR CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED..................................................................... 702 ERROR CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED.................................................................................................... 703 ERROR CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED.................... 704 ERROR CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED............................................. 705 ERROR CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED................................................................ 706 ERROR CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED................................................................................ 707 ERROR CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT)) IS DISPLAYED................................................................................................ 708 ERROR CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................................................. 709 ERROR CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED................................................................................. 710 ERROR CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED...................................................................................................... 711 ERROR CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED...................................................................................................... 712 ERROR CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED....................................................................................................... 713 ERROR CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED....................................................................................................... 714 ERROR CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED....................................................................................................... 715 ERROR CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED....................................................................................................... 716 ERROR CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED.......................................................................................................... 717 ERROR CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.......................................................................................................... 718 ERROR CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED......................................................................................................... 719 ERROR CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.......................................................................................................... 720 ERROR CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED............................................................................................. 721 ERROR CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.............................................................................................. 722 ERROR CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED..................................................................................................... 723 ERROR CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED...................................................................................................... 724 ERROR CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED.................................................................................................. 725 ERROR CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................... 726 ERROR CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED........................................................................................................ 727 ERROR CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED........................................................................... 728 ERROR CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................. 729 ERROR CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.................................................................................................. 730 ERROR CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED................................................................................................ 731 ERROR CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED................................................................................................. 732 ERROR CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED........................................................................................ 733 ERROR CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED......................................................................................... 734 ERROR CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED......................................................................................... 735 ERROR CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED.......................................................................................... 736 ACTION CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM................................................................................................................................ 737 ACTION CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM.............................................................................................................. 738 ACTION CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM.............................................................................................................. 739 ACTION CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM............................................................................................................ 741 ACTION CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SETTING SWITCH SYSTEM....................................................................................................... 743 ACTION CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM.................................................................................................................... 745 ACTION CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM........................................................................................................ 747 ACTION CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM........................................................................................................ 748 ACTION CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM........................................................................................................ 749 ACTION CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM............................................................................................................................. 750 ACTION CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM............................................................................................................... 752 ACTION CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM................................................................................................................. 753 ACTION CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM...................................................................................................... 754 ACTION CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM................................................................................................... 755 ACTION CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM......................................................................................................... 756 ACTION CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM.............................................................................................. 757 ACTION CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM.............................................................................................................. 758 ACTION CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM.............................................................................................................. 759 ACTION CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM................................................................................................................. 760 ACTION CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM................................................................................................................. 761 ACTION CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM.......................................................................................................... 762 ACTION CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM......................................................................................................... 763 ACTION CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM..................................................................................................... 764 ACTION CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM...................................................................................................... 765 ACTION CODE [WRK-25] DEFECTIVE BUCKET POSITIONER,LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION......................................................................................... 766 ACTION CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION............................................................................................................... 768 ACTION CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION.................................................................................................................. 770 ACTION CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION................................................................................................................ 772 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)................................................................................................................................................. 774 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 776 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 784 MONITOR SYSTEM DIAGRAM................................................................................................................................................................... 790 ERROR CODE [2F00MA] DEFECTIVE PARKING BRAKE SYSTEM....................................................................................................................................... 794 ERROR CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW......................................................................................................................... 796 ERROR CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW.................................................................................................................... 797 ERROR CODE [AA1ANX] AIR CLEANER 1 CLOGGED................................................................................................................................................ 798 ERROR CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED........................................................................ 800 ERROR CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED,DETECTION FAILURE)...................................................................... 801 ERROR CODE [B@BAZG] ENGINE OIL PRESSURE LOW.............................................................................................................................................. 802 ERROR CODE [B@BAZK] ENGINE OIL LEVEL LOW................................................................................................................................................. 803 ERROR CODE [B@BCNS] ENGINE WATER TEMPERATURE OVERHEATING................................................................................................................................. 804 ERROR CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL................................................................................................................................... 805 ERROR CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING................................................................................................................................ 806 ERROR CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING......................................................................................................................... 807 ERROR CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED.......................................................................................................... 808 ERROR CODE [D5ZHL6] STARTING SWITCH C (IGN""C"") INPUT FAILURE........................................................................................................................... 810 ERROR CODE [DA80L4] AUTO GREASE INPUT FAILURE............................................................................................................................................ 811 ERROR CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF......................................................................................... 812 ERROR CODE [DAF5KP] 5-V POWER SUPPLY OUTPUT FAILURE...................................................................................................................................... 814 ERROR CODE [DAF6KP] 24-V POWER SUPPLY OUTPUT FAILURE..................................................................................................................................... 815 ERROR CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION................................................................................................................................. 817 ERROR CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION......................................................................................................................... 818 ERROR CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) ..................................................................................... 819 ERROR CODE [DB2SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER) ........................................................................................... 820 ERROR CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ................................................................................... 821 ERROR CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) ................................................................................... 822 ERROR CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SW1) INPUT ERROR..................................................................................................... 823 ERROR CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [◇] (PANEL SW2) INPUT ERROR..................................................................................................... 824 ERROR CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE....................................................... 825 ERROR CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SW4) INPUT ERROR..................................................................................................... 826 ERROR CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE............................................................................................................................................. 827 ERROR CODE [DDS5L6] DECREASED STEERING OIL PRESSURE...................................................................................................................................... 828 ERROR CODE [DDY0LD] CANCEL SWITCH FAILURE................................................................................................................................................ 829 ERROR CODE [DGE2KX] ENGINE WATER TEMPERATURE SENSOR SYSTEM FAILURE....................................................................................................................... 830 ERROR CODE [DGE3L6] ABNORMAL CONNECTION OF ENGINE WATER TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM...................................................................................... 831 ERROR CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE...................................................................................................................... 832 ERROR CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE............................................................................................................... 833 ERROR CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE............................................................................................................................ 834 ERROR CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE....................................................................................................................................... 835 ERROR CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE......................................................................................................................................... 837 ERROR CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE........................................................................................................................................ 839 ERROR CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM........................................................................................................................... 840 ERROR CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE..................................................................................................... 841 ACTION CODE [MON-1] THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON (THE PARKING BRAKE INDICATOR SWITCH CIRCUIT SUFFERS A GROUND FAULT).... 843 ACTION CODE [MON-2] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT)............................................................ 845 ACTION CODE [MON-3] THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT)............................................................. 846 ACTION CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON............................................................................................................ 847 ACTION CODE [MON-5] THE ENGINE HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON.................................................................................................................. 849 ACTION CODE [MON-6] THE ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT ON.................................................................................................................. 850 ACTION CODE [MON-7] THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON.......................................................................................................... 851 ACTION CODE [MON-8] THE RADIATOR WATER VOLUME CAUTION LAMP DOES NOT LIGHT ON............................................................................................................. 852 ACTION CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON......................................................................................................... 853 ACTION CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON................................................................................................. 854 ACTION CODE [MON-11] THE STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT ON............................................................................................................... 855 ACTION CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [■] (PANEL SW1).......................................................................................................... 856 ACTION CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [◇] (PANEL SW2).......................................................................................................... 857 ACTION CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3).......................................................................................................... 858 ACTION CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4).......................................................................................................... 859 ACTION CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH........................................................................................................................................... 860 ACTION CODE [MON-17] DEFECTIVE CANCEL SWITCH............................................................................................................................................. 861 ACTION CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT).................................................................................................................. 862 ACTION CODE [MON-19] DEFECTIVE HEAD SENSOR............................................................................................................................................... 863 ACTION CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM)................................................ 864 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..................................................................................................................................... 865 H-1 THE MACHINE DOES NOT START........................................................................................................................................................... 866 H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED).......................................................................................... 868 H-3a THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK,THE UPHILL TRAVELING POWER IS WEAK, AND THE GEAR IS NOT SHIFTED............................................................... 869 H-3b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (IF THE LOCK-UP CLUTCH IS EQUIPPED)............................................................................................... 871 H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR.......................................................................................................................... 872 H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR......................................................................................................................... 874 H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH......................................................................................................................................... 876 H-7 THE STEERING WHEEL DOES NOT TURN..................................................................................................................................................... 877 H-8 THE STEERING WHEEL IS HEAVY.......................................................................................................................................................... 878 H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED................................................................................................................................. 879 H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING....................................................................................................................................... 879 H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT........................................................................................................................................ 879 H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL....................................................................................................................................... 880 H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED............................................................................................................................................. 881 H-14 THE PARKING BRAKE IS NOT RELEASED OR IS DRAGGED..................................................................................................................................... 882 H-15 THE LIFT ARM DOES NOT RISE.......................................................................................................................................................... 883 H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.............................................................................................................. 884 H-17 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT.................................................................................................................... 885 H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR)..................................................................................................... 885 H-19 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN........................................................................................................................................ 885 H-20 THE LIFT ARM WOBBLES DURING OPERATION............................................................................................................................................... 885 H-21 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE",THE LIFT ARM FALLS TEMPORARILY............................................................................................ 886 H-22 THE BUCKET DOES NOT TILT BACK....................................................................................................................................................... 887 H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT................................................................................................................... 888 H-24 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING-BACK...................................................................................................................... 889 H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET..................................................................................................................................... 889 H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.......................................................................................................................................... 889 H-27 THE BUCKET WOBBLES DURING TRAVEL WITH LOAD (THE WORK EQUIPMENT VALVE IS SET TO "HOLD").............................................................................................. 890 H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "TILT",THE BUCKET FALLS TEMPORARILY............................................................................................... 890 H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY............................................................................................................ 891 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................................................................................................ 892 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................................... 893 CONNECTOR LAYOUT DRAWING................................................................................................................................................................. 901 ELECTRICAL SYSTEM DIAGRAM................................................................................................................................................................ 907 ACTION CODE [E-1-a] (THE ENGINE DOES NOT START. (STARTING SYSTEM))....................................................................................................................... 908 ACTION CODE [E-1-b] (THE ENGINE DOES NOT START.(ENGINE STOP SOLENOID SYSTEM))............................................................................................................ 912 ACTION CODE [E-2] (THE ENGINE DOES NOT STOP)............................................................................................................................................. 914 ACTION CODE [E-3] (PREHEATING IS IMPOSSIBLE OR STAYS OPERATED)........................................................................................................................... 916 ACTION CODE [E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED)............................................................................................................................ 918 ACTION CODE [E-5] (ALL OF THE BUCKET POSITIONER, LIFT ARM KICK-OUT, AND FLOATING HOLDER DO NOT FUNCTION)................................................................................. 920 ACTION CODE [E-6] (THE LIFT ARM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED)........................................................................................................ 922 ACTION CODE [E-7] (THE BUCKET POSITIONER DOES NOT FUNCTION OR CANNOT BE RELEASED)........................................................................................................ 924 ACTION CODE [E-8] (THE LIFT ARM FLOATING HOLDER DOES NOT FUNCTION OR CANNOT BE RELEASED)................................................................................................. 926 ACTION CODE [E-9] (THE FRONT WIPER DOES NOT FUNCTION).................................................................................................................................... 927 ACTION CODE [E-10] (THE REAR WIPER DOES NOT FUNCTION).................................................................................................................................... 930 ACTION CODE [E-11] (THE SIDE WIPER DOES NOT FUNCTION (OPT)).............................................................................................................................. 931 ACTION CODE [E-12] (THE WIND WASHER DOES NOT FUNCTION)................................................................................................................................... 932 ACTION CODE [E-13] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON)............................................................................................................................ 935 ACTION CODE [E-14] (THE HEADLAMP (HI BEAM) DOES NOT LIGHT ON)............................................................................................................................ 938 ACTION CODE [E-15] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP))................................................................................................................... 940 ACTION CODE [E-16] (THE TURN SIGNAL DOES NOT BLINK)...................................................................................................................................... 941 ACTION CODE [E-17] (THE HORN DOES NOT SOUND)............................................................................................................................................. 943 ACTION CODE [E-18] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP).................................................................................................................. 945 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................................................................................................... 948 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................................... 949 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)............................................................................................................................ 953 S-2 ENGINE DOES NOT START................................................................................................................................................................ 954 (1) ENGINE DOES NOT TURN............................................................................................................................................................. 954 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)......................................................................................................... 955 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....................................................................................................... 956 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................................................................................................. 957 S-4 ENGINE STOPS DURING OPERATIONS....................................................................................................................................................... 958 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)............................................................................................................................................ 959 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................................................................................................. 960 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....................................................................................................................................... 961 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................................................................................. 962 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................................................................................... 963 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................................................................................... 964 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN............................................................................................................. 965 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................... 966 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)................................................................................................................................................ 967 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................................................................................... 968 S-15 ABNORMAL NOISE IS MADE.............................................................................................................................................................. 969 S-16 VIBRATION IS EXCESSIVE.............................................................................................................................................................. 970 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................... 971 METHOD OF USING MANUAL........................................................................................................................................................................... 972 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................................................... 973 SPECIAL TOOL LIST................................................................................................................................................................................ 976 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY...................................................................................................................................................... 979 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY............................................................................................................................................... 983 REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY...................................................................................................................................... 988 REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY................................................................................................................................................. 990 REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP.................................................................................................................................................. 990 REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY............................................................................................................................................... 993 REMOVAL AND INSTALLATION OF FAN AND FAN MOTOR ASSEMBLY........................................................................................................................................... 995 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY................................................................................................................................................... 996 REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE............................................................................................................................................. 998 REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY...........................................................................................................................1002 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY................................................................................................................................................1006 DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY....................................................................................................................................1019 DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY...............................................................................................................................................1034 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION)...................................................................................................................1045 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION)....................................................................................................................1049 REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY...................................................................................................................................................1055 REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY..................................................................................................................................................1058 DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY................................................................................................................................................1059 DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY................................................................................................................................................1076 REMOVAL AND INSTALLATION OF CENTER HINGE PIN.....................................................................................................................................................1095 REMOVAL AND INSTALLATION OF CAB ASSEMBLY.........................................................................................................................................................1102 REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY.........................................................................................................................................1103 REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY..................................................................................................................1106 REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY...........................................................................................................................1107 REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY.......................................................................................................................................1108 REMOVAL AND INSTALLATION OF E.C.S.S. VALVE ASSEMBLY..............................................................................................................................................1109 REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY........................................................................................................................................1110 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY)...........................................................................................1112 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY..............................................................................................................................................1119 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY..............................................................................................................................................1121 REMOVAL AND INSTALLATION OF COUNTER WEIGHT.......................................................................................................................................................1125 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT.................................................................................................................................................1126 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY..................................................................................................................................1129 DISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY................................................................................................................................................1130 90 OTHERS............................................................................................................................................................................................1140 POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH).........................................................................................................................1141 POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)............................................................................................................................1142 BRAKE OIL CIRCUIT DIAGRAM........................................................................................................................................................................1143 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.........................................................................................................................................................1144 ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................................................................................1145 1/8 (1/4)....................................................................................................................................................................................1145 1/8 (2/4)....................................................................................................................................................................................1146 1/8 (3/4)....................................................................................................................................................................................1147 1/8 (4/4)....................................................................................................................................................................................1148 2/8 (1/4)....................................................................................................................................................................................1149 2/8 (2/4)....................................................................................................................................................................................1150 3/8 (3/4)....................................................................................................................................................................................1151 4/8 (4/4)....................................................................................................................................................................................1152 3/8..........................................................................................................................................................................................1153 4/8..........................................................................................................................................................................................1154 5/8..........................................................................................................................................................................................1155 6/8..........................................................................................................................................................................................1156 7/8..........................................................................................................................................................................................1157 8/8..........................................................................................................................................................................................1158
DESCRIPTION:
KOMATSU WA400-5 SHOP MANUAL SEBM028005 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
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