Komatsu WA400-5 Wheel Loader Shop Manual SEBM028007- PDF DOWNLOAD

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Komatsu WA400-5 Wheel Loader Shop Manual SEBM028007- PDF DOWNLOAD

FILE DETAILS:

Komatsu WA400-5 Wheel Loader Shop Manual SEBM028007- PDF DOWNLOAD

Language : English
Pages : 1232
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA400-5 Wheel Loader Shop Manual SEBM028007- PDF DOWNLOAD

Machine model     Serial number

• WA400-5                70001 and up

COVER 1
CONTENTS . 2
LIST OF REVISED PAGES 3
SAFETY . 9
SAFETY NOTICE 9
FOREWORD . 11
GENERAL 11
HOW TO READ THE SHOP MANUAL 12
HOISTING INSTRUCTIONS 13
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER . 14
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE . 18
ELECTRIC WIRE CODE . 21
CONVERSION TABLE . 22
UNITS 28
01 GENERAL . 29
GENERAL ASSEMBLY DRAWING . 30
SPECIFICATIONS . 31
WEIGHT TABLE . 35
LIST OF LUBRICANT AND COOLANT 37
10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD 39
COOLING SYSTEM . 40
ENGINE MOUNT, TRANSMISSION MOUNT . 41
POWER TRAIN 42
POWER TRAIN SYSTEM DIAGRAM . 43
DRIVE SHAFT (PROPELLER SHAFT) 46
TORQUE CONVERTER, TRANSMISSION PIPING 47
TORQUE CONVERTER . 48
TRANSMISSION . 56
TRANSMISSION CONTROL VALVE . 72
AXLE . 90
DIFFERENTIAL . 92
FINAL DRIVE 104
AXLE MOUNTING, CENTER HINGE PIN 112
STEERING PIPING 116
STEERING COLUMN, ORBIT-ROLL 117
STEERING VALVE . 118
ORBIT-ROLL VALVE . 133
STOP VALVE . 137
STEERING PUMP, SWITCH PUMP . 138
EMERGENCY STEERING PUMP (OP) . 140
EMERGENCY STEERING MOTOR (OP) 141
STEERING CYLINDER 142
JOYSTICK STEERING LEVER (OP) . 144
STEERING LEVER (OP) 145
STEERING SWITCH VALVE (OP) . 147
BRAKE PIPING . 148
BRAKE VALVE 150
CHARGE VALVE . 157
ACCUMULATOR (FOR BRAKE) 161
BRAKE 163
PARKING BRAKE CONTROL 168
PARKING BRAKE 169
PARKING BRAKE SOLENOID VALVE . 171
PARKING BRAKE EMERGENCY RELEASE VALVE 173
HYDRAULIC PIPING . 174
WORK EQUIPMENT CONTROL LEVER . 177
HYDRAULIC TANK . 179
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS . 181
PPC RELIEF VALVE . 183
ECSS VALVE . 185
WORK EQUIPMENT CONTROL VALVE . 187
WORK EQUIPMENT PPC VALVE . 204
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) 210
EPC SOLENOID VALVE (OP) 216
SHUT OFF VALVE (OP) 219
ATTACHMENT PPC VALVE (OP) 220
COOLING FAN MOTOR 224
COOLING FAN MOTOR DRIVE PUMP . 229
WORK EQUIPMENT LINKAGE . 237
BUCKET . 239
BUCKET POSITIONER, LIFT ARM KICK-OUT . 240
WORK EQUIPMENT CYLINDER 246
CAB 247
AIR CONDITIONER (OP) . 248
MACHINE MONITORING SYSTEM 249
MACHINE MONITOR 256
TRANSMISSION CONTROL SYSTEM 320
TRANSMISSION CONTROLLER 348
JOY STICK STEERING CONTROL SYSTEM (OP) . 350
WORK EQUIPMENT CONTROLLER 356
ELECTRIC TRANSMISSION CONTROL 358
KICK DOWN, HOLD SWITCH . 362
ENGINE STARTING CIRCUIT 363
ENGINE STOP CIRCUIT 365
PREHEATING CIRCUIT . 366
ENGINE POWER MODE SELECTOR CIRCUIT . 367
PARKING BRAKE CIRCUIT 368
SENSORS 372
20 TESTING AND ADJUSTING . 383
STANDARD VALUE TABLE . 384
STANDARD VALUE TABLE FOR ENGINE 384
STANDARD VALUE TABLE FOR CHASSIS . 385
TESTING AND ADJUSTING 393
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 395
MEASURING ENGINE SPEED . 396
MEASURING EXHAUST COLOR 398
MEASURING EXHAUST TEMPERATURE 399
ADJUSTING VALVE CLEARANCE 400
MEASURING COMPRESSION PRESSURE . 402
MEASURING BLOW-BY PRESSURE . 403
MEASURING ENGINE OIL PRESSURE 404
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) . 405
TESTING AND ADJUSTING FUEL INJECTION TIMING 406
ADJUSTING ENGINE SPEED SENSOR 407
BLEEDING AIR FROM FUEL CIRCUIT . 408
ADJUSTING ENGINE STOP SOLENOID . 409
ADJUSTING ACCELERATOR PEDAL 411
ADJUSTING TRANSMISSION SPEED SENSOR 413
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE . 414
DRAWING OF SPECIAL TOOL 418
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT 419
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS . 420
TESTING AND ADJUSTING STEERING CONTROL . 422
TESTING AND ADJUSTING STEERING OIL PRESSURE 423
TESTING HYDRAULIC FAN 425
MEASURING BRAKE OIL PRESSURE . 426
TESTING WEAR OF WHEEL BRAKE DISC . 428
BLEEDING AIR FROM BRAKE CIRCUIT 429
TESTING WEAR OF PARKING BRAKE DISC . 430
MANUAL RELEASE METHOD FOR PARKING BRAKE 431
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 432
TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE . 434
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 436
TESTING AND ADJUSTING BUCKET POSITIONER 438
TESTING AND ADJUSTING LIFT ARM KICK-OUT 439
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP . 440
ADJUSTING MACHINE MONITOR 441
TESTING AND ADJUSTING LOAD METER . 444
BLEEDING AIR . 448
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 449
RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT 449
Pm CLINIC INSPECTION TABLE . 450
TROUBLESHOOTING 453
POINTS TO REMEMBER WHEN TROUBLESHOOTING 454
SEQUENCE OF EVENTS IN TROUBLESHOOTING 455
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 456
CHECKS BEFORE TROUBLESHOOTING 464
EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM 465
SPECIAL FUNCTIONS OF MACHINE MONITOR . 466
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS 501
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . 510
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE) . 537
CONNECTOR TYPES AND MOUNTING LOCATIONS . 539
CONNECTOR LAYOUT DRAWING . 548
TRANSMISSION CONTROL SYSTEM DIAGRAM 554
FAILURE CODE [1500L1] (DOUBLE ENGAGEMENT DETECTED) IS DISPLAYED 557
FAILURE CODE [15SAL1] (F_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 558
FAILURE CODE [15SALH] (F_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 559
FAILURE CODE [15SBL1] (R_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 560
FAILURE CODE [15SBLH] (R_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 561
FAILURE CODE [15SEL1] (1ST_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 562
FAILURE CODE [15SELH] (1ST_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 563
FAILURE CODE [15SFL1] (2ND_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 564
FAILURE CODE [15SFLH] (2ND_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 565
FAILURE CODE [15SGL1] (3RD_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 566
FAILURE CODE [15SGLH] (3RD_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 567
FAILURE CODE [15SHL1] (4TH_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED . 568
FAILURE CODE [15SHLH] (4TH_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED 569
FAILURE CODE [15SJL1] (LOCKUP_ECMV FILL SWITCH SYSTEM SHORT-CIRCUITED) IS DISPLAYED 570
FAILURE CODE [15SJLH] (LOCKUP_ECMV FILL SWITCH SYSTEM DISCONNECTED) IS DISPLAYED . 571
FAILURE CODE [989F00] (TRANSMISSION PROTECTION CAUTION) IS DISPLAYED . 572
FAILURE CODE [B@C7NS] (REAR BRAKE COOLING OIL OVERHEAT) IS DISPLAYED . 573
FAILURE CODE [D150KA] (EMERGENCY STEERING RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED . 574
FAILURE CODE [D150KB] (EMERGENCY STEERING RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED . 575
FAILURE CODE [D160KA] (BACKUP LAMP RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 576
FAILURE CODE [D160KB] (BACKUP LAMP RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 577
FAILURE CODE [D191KA] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED . 578
FAILURE CODE [D191KB] (NEUTRAL SAFETY RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED . 580
FAILURE CODE [D192KA] (TRAVEL DAMPER RELAY OUTPUT SYSTEM DISCONNECTED) IS DISPLAYED 582
FAILURE CODE [D192KB] (TRAVEL DAMPER RELAY OUTPUT SYSTEM GROUNDED) IS DISPLAYED 583
FAILURE CODE [D198KB] (GROUND FAULT IN LOW TEMPERATURE BYPASS RELAY SYSTEM) 584
FAILURE CODE [D198KY] (HOT SHORT IN LOW-TEMPERATURE BYPASS RELAY SYSTEM) . 585
FAILURE CODE [DAQ0KK] (CONTROLLER POWER SUPPLY VOLTAGE LOWERED) IS DISPLAYED . 586
FAILURE CODE [DAQ2KK] (DEFECTIVE SOLENOID POWER SUPPLY SYSTEM) IS DISPLAYED 587
FAILURE CODE [DAQ9KQ] (MODEL SELECTION SIGNAL MISMATCH) IS DISPLAYED . 588
FAILURE CODE [DDK3KA] (RIGHT FNR SWITCH SIGNAL NOT INPUT) IS DISPLAYED . 590
FAILURE CODE [DDK3KB] (MULTIPLE RIGHT FNR SWITCH SIGNAL INPUT) IS DISPLAYED 592
FAILURE CODE [DDK4KA] (JOYSTICK FORWARD/REVERSE SWITCH SIGNAL IS NOT INPUT) IS DISPLAYED . 595
FAILURE CODE [DDK4KB] (MULTIPLE JOYSTICK FORWARD/REVERSE SWITCH SIGNALS ARE INPUT) IS DISPLAYED 597
FAILURE CODE [DDK5LD] (SHORT CIRCUIT WITH POWER SOURCE IN JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH) IS DISPLAYED 599
FAILURE CODE [DDK6KA] (FORWARD-REVERSE LEVER SIGNAL NOT INPUT) IS DISPLAYED 600
FAILURE CODE [DDK6KB] (MULTIPLE FORWARD-REVERSE LEVER SIGNAL INPUT) IS DISPLAYED . 602
FAILURE CODE [DDS5KA] (STEERING PRESSURE SWITCH DISCONNECTED) IS DISPLAYED . 604
FAILURE CODE [DDS5KB] (STEERING PRESSURE SWITCH GROUNDED) IS DISPLAYED . 605
FAILURE CODE [DDT0L4] (MANUAL/AUTO-SHIFT SELECTOR SWITCH SELECTION FAILURE) IS DISPLAYED . 606
FAILURE CODE [DDT4LD] (GROUND FAULT OF TRANSMISSION CUT-OFF SETTING SWITCH) IS DISPLAYED . 608
FAILURE CODE [DDW9LD] (GROUND FAULT OF KICKDOWN SWITCH SYSTEM) IS DISPLAYED 609
FAILURE CODE [DDWLLD] (GROUND FAULT OF HOLD SWITCH SYSTEM) IS DISPLAYED 612
FAILURE CODE [DF10KA] (NO INPUT OF GEARSHIFT LEVER SIGNAL) IS DISPLAYED 614
FAILURE CODE [DF10KB] (INPUT OF MULTIPLE GEARSHIFT LEVER SIGNALS) IS DISPLAYED . 616
FAILURE CODE [DGF1KX] (TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE) IS DISPLAYED 618
FAILURE CODE [DGR2KA] (REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM DISCONNECTION) IS DISPLAYED 619
FAILURE CODE [DGR2KB] (GROUND FAULT OF REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED 620
FAILURE CODE [DHT1KX] TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL DISCONTINUITY) IS DISPLAYED . 621
FAILURE CODE [DLE2KA] (ENGINE REVOLUTION SENSOR SYSTEM DISCONTINUITY) IS DISPLAYED . 622
FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR FAILURE) IS DISPLAYED 623
FAILURE CODE [DLT3KA] (SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM DISCONTINUITY) IS DISPLAYED 624
FAILURE CODE [DT20KB] (GROUND FAULT OF BUILT-IN INDICATOR LAMP SYSTEM OF TRANSMISSION CUT-OFF SWITCH) IS DISPLAYED . 625
FAILURE CODE [DW7BKA] (FAN PUMP REVERSE SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 626
FAILURE CODE [DW7BKB] (FAN PUMP REVERSE SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 627
FAILURE CODE [DW7CKA] (SWITCH PUMP CUT-OFF RELAY DISCONTINUITY) IS DISPLAYED . 628
FAILURE CODE [DW7CKB] (SWITCH PUMP CUT-OFF RELAY GROUND FAULT) IS DISPLAYED 629
FAILURE CODE [DX16KA] (FAN PUMP EPC SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 630
FAILURE CODE [DX16KB] (FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 631
FAILURE CODE [DXH1KA] (LOCK-UP CLUTCH _ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 632
FAILURE CODE [DXH1KB] (LOCK-UP CLUTCH _ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 633
FAILURE CODE [DXH4KA] (1ST_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 634
FAILURE CODE [DXH4KB] (1ST_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 635
FAILURE CODE [DXH5KA] (2ND_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 636
FAILURE CODE [DXH5KB] (2ND_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 637
FAILURE CODE [DXH6KA] (3RD_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 638
FAILURE CODE [DXH6KB] (3RD_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 639
FAILURE CODE [DXH7KA] (R_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 640
FAILURE CODE [DXH7KB] (R_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 641
FAILURE CODE [DXH8KA] (F_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 642
FAILURE CODE [DXH8KB] (F_ECMV SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 643
FAILURE CODE [DXHHKA] (4TH_ECMV SOLENOID SYSTEM DISCONTINUITY) IS DISPLAYED 644
FAILURE CODE [DXHHKB] (4TH_ECMV SOLENOID SYSTEM SHORT-CIRCUITING) IS DISPLAYED . 645
FAILURE CODE [DY30MA] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) 646
FAILURE CODE [DY30MC] (MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE (MALFUNCTION IN MANUAL MODE)) 648
ACTION CODE [TM-1] DISCONTINUITY OR HOT SHORT-CIRCUITING OF KICKDOWN SWITCH SYSTEM . 650
ACTION CODE [TM-2] HOLD SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING 652
ACTION CODE [TM-3] TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE 654
ACTION CODE [TM-4] NEUTRALIZER SIGNAL (PARKING BRAKE SWITCH SIGNAL) SYSTEM FAILURE . 656
ACTION CODE [TM-5] EMERGENCY STEERING SWITCH (MOTOR-DRIVEN EMERGENCY STEERING OPERATION SWITCH) SIGNAL SYSTEM FAILURE 658
ACTION CODE [TM-6] TRANSMISSION CUT-OFF SWITCH SYSTEM DISCONTINUITY OR GROUND FAULT 660
ACTION CODE [TM-7] TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM DISCONTINUITY OR HOT SHORT-CIRCUITING 661
ACTION CODE [TM-8] TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORT-CIRCUITING 662
ACTION CODE [TM-9] JOYSTICK SHIFT_UP/SHIFT_DOWN SWITCH SYSTEM FAILURE (DISCONTINUITY OR GROUND FAULT) 663
ACTION CODE [TM-10-a] JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE 664
ACTION CODE [TM-10-b] STARTING SWITCH “C” (IGN_C) SIGNAL SYSTEM FAILURE 666
ACTION CODE [TM-11] FNR SWITCH MODE CHANGE OVER SWITCH SYSTEM FAILURE 668
ACTION CODE [TM-12] ENGINE POWER MODE SWITCH DISCONTINUITY OR GROUND FAULT . 670
ACTION CODE [TM-13] TRAVEL DAMPER ON/OFF SWITCH DISCONTINUITY OR GROUND FAULT . 671
ACTION CODE [TM-14] HYDRAULIC FAN REVERSE SWITCH SIGNAL SYSTEM HOT SHORT-CIRCUITING OR DISCONTINUITY . 672
ACTION CODE [TM-15] MOTOR-DRIVEN EMERGENCY STEERING RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING . 673
ACTION CODE [TM-16] TRAVEL DAMPER RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING . 674
ACTION CODE [TM-17] SWITCH PUMP CUT-OFF RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING . 675
ACTION CODE [TM-18] BACK LAMP RELAY OUTPUT SYSTEM HOT SHORT-CIRCUITING . 676
ACTION CODE [TM-19] NEUTRAL OUTPUT SYSTEM HOT SHORT-CIRCUITING . 677
ACTION CODE [TM-20] FECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING . 678
ACTION CODE [TM-21] RECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING . 679
ACTION CODE [TM-22] 1ST ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 680
ACTION CODE [TM-23] 2ND ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 681
ACTION CODE [TM-24] 3RD ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 682
ACTION CODE [TM-25] 4TH ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 683
ACTION CODE [TM-26] LOCK-UP ECMV SOLENOID SYSTEM HOT SHORT-CIRCUITING 684
ACTION CODE [TM-27] FAN PUMP EPC SOLENOID SYSTEM HOT SHORT-CIRCUITING 685
ACTION CODE [TM-28] FAN REVERSE SOLENOID SYSTEM HOT SHORT-CIRCUITING . 686
ACTION CODE [TM-29] SPEED SENSOR (TRANSMISSION OUTPUT SHAFT REVOLUTION) SYSTEM FAILURE . 687
ACTION CODE [TM-30] TRAVEL DAMPER SOLENOID SYSTEM DISCONTINUITY OR GROUND FAULT 688
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE) 689
CONNECTOR TYPES AND MOUNTING LOCATIONS . 691
CONNECTOR LAYOUT DRAWING . 700
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM 706
ERROR CODE [D193KA] (DEFECTIVE JOYSTICK STEERING CUT RELAY SYSTEM (MAIN SYSTEM DISCONNECTED)) IS DISPLAYED . 709
ERROR CODE [D193KB] (THE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM IS GROUNDED PROPERLY) IS DISPLAYED 710
ERROR CODE [DB90KK] (LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY) IS DISPLAYED . 711
ERROR CODE [DB92KK] (DEFECTIVE SOLENOID ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED . 712
ERROR CODE [DB95KX] (DEFECTIVE 5 V ELECTRIC POWER SUPPLY SYSTEM) IS DISPLAYED 714
ERROR CODE [DD1ALD] (DEFECTIVE REMOTE POSITIONER UP SET SWITCH (GROUND FAULT)) IS DISPLAYED 716
ERROR CODE [DD1BLD] (DEFECTIVE REMOTE POSITIONER DOWN SET SWITCH (GROUND FAULT)) IS DISPLAYED 717
ERROR CODE [DFA0KM] (DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT LEVER) IS DISPLAYED . 718
ERROR CODE [DK59KA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 719
ERROR CODE [DK59KY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORT CIRCUIT)) IS DISPLAYED 720
ERROR CODE [DK59L8] (DEFECTIVE LIFT ARM EPC POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT) IS DISPLAYED . 721
ERROR CODE [DK5AKA] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OF MAIN) (DISCONNECTION, GROUND OF SUB)) IS DISPLAYED 722
ERROR CODE [DK5AKY] (DEFECTIVE LIFT ARM EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED . 723
ERROR CODE [DK5BKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 724
ERROR CODE [DK5BKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (MAIN SHORTED)) IS DISPLAYED 725
ERROR CODE [DK5BL8] (DEFECTIVE INPUT SIGNAL FOR BUCKET EPC LEVER POTENTIOMETER SYSTEM (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED . 726
ERROR CODE [DK5CKA] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED . 727
ERROR CODE [DK5CKY] (DEFECTIVE BUCKET EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED . 728
ERROR CODE [KD5DKA] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED . 729
ERROR CODE [DK5DKY] (DEFECTIVE 3RD VALVE LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORT CIRCUIT)) IS DISPLAYED . 730
ERROR CODE [DK5DL8] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DISPLACEMENT OF MAIN AND SUB-CIRCUIT)) IS DISPLAYED 731
ERROR CODE [DK5EKA] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED 732
ERROR CODE [DK5EKY] (DEFECTIVE 3RD VALVE EPC LEVER POTENTIOMETER SYSTEM (SHORT SUB-CIRCUIT)) IS DISPLAYED 733
ERROR CODE [DK5FKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT DISCONTINUITY OR GROUND FAULT)) IS DISPLAYED . 734
ERROR CODE [DK5FKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)) IS DISPLAYED . 735
ERROR CODE [DK5FKM] (JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION) IS DISPLAYED 736
ERROR CODE [DK5FL8] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM INPUT SIGNAL (DEVIATION OF POSITIONAL SIGNALS OF MAIN AND SUB-CIRCUITS)) IS DISPLAYED 737
ERROR CODE [DG5GKA] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (DISCONNECTION OR GROUND FAULT OF SUB-CIRCUIT)) IS DISPLAYED . 738
ERROR CODE [DK5GKY] (DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER SYSTEM (SUB-CIRCUIT SHORT CIRCUIT)) IS DISPLAYED 739
ERROR CODE [DKA0KA] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (DISCONNECTION OR GROUND FAULT)) IS DISPLAYED 740
ERROR CODE [DKA0KY] (DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (SHORT CIRCUIT) IS DISPLAYED . 741
ERROR CODE [DLE2LC] (DEFECTIVE ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED 742
ERROR CODE [DLT3LC] (DEFECTIVE TRANSMISSION OUTPUT AXIS SPEED SENSOR SYSTEM (DISCONNECTED)) IS DISPLAYED . 743
ERROR CODE [DUM1KB] (REMOTE POSITIONER RAISE LAMP SYSTEM GROUND FAULT) IS DISPLAYED 744
ERROR CODE [DUM2KB] (REMOTE POSITIONER LOWER LAMP SYSTEM GROUND FAULT) IS DISPLAYED 745
ERROR CODE [DW4PKA] (DISCONNECTED LIFT ARM RAISE EPC SOLENOID SYSTEM) IS DISPLAYED . 746
ERROR CODE [DW4PKB] (LIFT ARM RAISE EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 747
ERROR CODE [DW4QKA] (DISCONNECTED LIFT ARM LOWER EPC SOLENOID SYSTEM) IS DISPLAYED . 748
ERROR CODE [DW4QKB] (LIFT ARM LOWER EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 749
ERROR CODE [DW4RKA] (DISCONNECTED BUCKET TILT EPC SOLENOID SYSTEM) IS DISPLAYED 750
ERROR CODE [DW4RKB] (BUCKET TILT EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 751
ERROR CODE [DW4SKA] (BUCKET DUMP EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 752
ERROR CODE [DW4SKB] (BUCKET DUMP EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 753
ERROR CODE [DWM1KA] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 754
ERROR CODE [DWM1KB] (WORK EQUIPMENT NEUTRAL LOCK SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 755
ERROR CODE [DWN6KA] (LIFT ARM RAISE MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED . 756
ERROR CODE [DWN6KB] (LIFT ARM RAISE MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED 757
ERROR CODE [DWN7KA] (LIFT ARM FLOATING MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 758
ERROR CODE [DWN7KB] (LIFT ARM FLOATING MAGNET DETENT SYSTEM GROUND FAULT) IS DISPLAYED . 759
ERROR CODE [DWN8KA] (BUCKET TILT MAGNET DETENT SYSTEM DISCONNECTION) IS DISPLAYED 760
ERROR CODE [DWN8KB] (BUCKET TILT MAGNET DETENT SYSTEM FAILURE (POWER SUPPLY SYSTEM GROUND FAULT)) IS DISPLAYED . 761
ERROR CODE [DXHJKA] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 762
ERROR CODE [DXHJKB] (3RD VALVE EXTENSION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 763
ERROR CODE [DXHKKA] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED 764
ERROR CODE [DXHKKB] (3RD VALVE RETRACTION EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 765
ERROR CODE [DXHLKA] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 766
ERROR CODE [DXHLKB] (JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED . 767
ERROR CODE [DXHMKA] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM DISCONNECTION) IS DISPLAYED . 768
ERROR CODE [DXHMKB] (JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT) IS DISPLAYED 769
ACTION CODE [WRK-1] DEFECTIVE LIFT ARM LOCK SWITCH SYSTEM 770
ACTION CODE [WRK-2] DEFECTIVE REMOTE POSITIONER RAISE SETTING SWITCH SYSTEM 771
ACTION CODE [WRK-3] DEFECTIVE REMOTE POSITIONER LOWER SETTING SWITCH SYSTEM 772
ACTION CODE [WRK-4] DEFECTIVE REMOTE POSITIONER RAISE SELECTION SWITCH SYSTEM 774
ACTION CODE [WRK-5] DEFECTIVE REMOTE POSITIONER LOWER ON/OFF SWITCH SYSTEM . 776
ACTION CODE [WRK-6] DEFECTIVE BUCKET CYLINDER PROXIMITY SWITCH SYSTEM 778
ACTION CODE [WRK-7] DEFECTIVE BUCKET CYLINDER FULL STROKE DETECTION SWITCH SYSTEM 780
ACTION CODE [WRK-8] DEFECTIVE SEMI-AUTOMATIC DIGGING HARD SELECTION SWITCH SYSTEM 781
ACTION CODE [WRK-9] DEFECTIVE SEMI-AUTOMATIC DIGGING SOFT SELECTION SWITCH SYSTEM 782
ACTION CODE [WRK-10] DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM . 784
ACTION CODE [WRK-11] DEFECTIVE JOYSTICK STEERING SPEED HI/LO SWITCH SYSTEM . 786
ACTION CODE [WRK-12] DEFECTIVE JOYSTICK SOLENOID CUT RELAY OUTPUT SYSTEM . 787
ACTION CODE [WRK-13] HOT SHORT-CIRCUITED LIFT ARM RAISE MAGNET DETENT OUTPUT SYSTEM 788
ACTION CODE [WRK-14] HOT SHORT-CIRCUITED LIFT ARM FLOATING MAGNET DETENT OUTPUT SYSTEM . 789
ACTION CODE [WRK-15] HOT SHORT-CIRCUITED BUCKET TILT MAGNET DETENT OUTPUT SYSTEM . 790
ACTION CODE [WRK-16] HOT SHORT-CIRCUITED WORK EQUIPMENT NEUTRAL LOCK SOLENOID OUTPUT SYSTEM 791
ACTION CODE [WRK-17] HOT SHORT-CIRCUITED LIFT ARM RAISE EPC SOLENOID SYSTEM 792
ACTION CODE [WRK-18] HOT SHORT-CIRCUITED LIFT ARM LOWER EPC SOLENOID SYSTEM 793
ACTION CODE [WRK-19] HOT SHORT-CIRCUITED BUCKET TILT EPC SOLENOID SYSTEM . 794
ACTION CODE [WRK-20] HOT SHORT-CIRCUITED BUCKET DUMP EPC SOLENOID SYSTEM . 795
ACTION CODE [WRK-21] HOT SHORT-CIRCUITED 3 VALVES EXTENSION EPC SOLENOID SYSTEM 796
ACTION CODE [WRK-22] HOT SHORT-CIRCUITED 3 VALVES RETRACTION EPC SOLENOID SYSTEM . 797
ACTION CODE [WRK-23] HOT SHORT-CIRCUITED JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM . 798
ACTION CODE [WRK-24] HOT SHORT-CIRCUITED JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM 799
ACTION CODE [WRK-25] DEFECTIVE BUCKET POSITIONER, LIFT ARM KICK-OUT AND FLOATING HOLDING FUNCTION 800
ACTION CODE [WRK-26] DEFECTIVE LIFT ARM KICK-OUT FUNCTION AND CANCELLATION . 802
ACTION CODE [WRK-27] DEFECTIVE BUCKET LEVELER FUNCTION AND CANCELLATION 804
ACTION CODE [WRK-28] DEFECTIVE LIFT ARM FLOATING HOLDING AND CANCELLATION 806
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE) . 809
CONNECTOR TYPES AND MOUNTING LOCATIONS . 811
CONNECTOR LAYOUT DRAWING . 820
MONITOR SYSTEM DIAGRAM . 826
FAILURE CODE [2F00MA] DEFECTIVE PARKING BRAKE SYSTEM . 830
FAILURE CODE [2G42ZG] ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW . 832
FAILURE CODE [2G43ZG] ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW 833
FAILURE CODE [AA1ANX] AIR CLEANER 1 CLOGGED 834
FAILURE CODE [AB00L6] DEFECTIVE BATTERY CHARGING CIRCUIT (ALTERNATOR TERMINAL R SIGNAL DETECTED WHEN ENGINE STOPPED 836
FAILURE CODE [AB00MA] DEFECTIVE BATTERY CHARGING CIRCUIT (NO ALTERNATOR TERMINAL R SIGNAL DETECTED, DETECTION FAILURE) . 837
FAILURE CODE [B@BAZG] ENGINE OIL PRESSURE LOW 838
FAILURE CODE [B@BAZK] ENGINE OIL LEVEL LOW . 839
FAILURE CODE [B@BCNS] ENGINE COOLANT TEMPERATURE OVERHEATING . 840
FAILURE CODE [B@BCZK] ALARM INDICATING LOW COOLANT LEVEL . 841
FAILURE CODE [B@HANS] HYDRAULIC OIL TEMPERATURE OVERHEATING 842
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL TEMPERATURE OVERHEATING . 843
FAILURE CODE [D182KZ] THE PREHEATER RELAY COIL IS DISCONNECTED OR SHIRT-CIRCUITED 844
FAILURE CODE [D5ZHL6] STARTING SWITCH C (IGN “C”) INPUT FAILURE 846
FAILURE CODE [DA80L4] AUTO GREASE INPUT FAILURE 847
FAILURE CODE [DAF3KK] SW POWER SUPPLY (FOR OPERATION) = ON AND NSW POWER SUPPLY (FOR MEMORY) = OFF . 848
FAILURE CODE [DAF5KP] 5-V POWER SUPPLY OUTPUT FAILURE 850
FAILURE CODE [DAF6KP] 24-V POWER SUPPLY OUTPUT FAILURE . 852
FAILURE CODE [DAFBKM] WRONG INFORMATION ON MODEL SELECTION . 854
FAILURE CODE [DAFSKQ] WRONG INFORMATION ON METER DISPLAY SELECTION . 855
FAILURE CODE [DAQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER) 856
FAILURE CODE [DB2SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND ENGINE CONTROLLER . 857
FAILURE CODE [DBQSKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER) 858
FAILURE CODE [DB9SKR] S-NET COMMUNICATION FAILURE (BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER . 859
FAILURE CODE [DD15LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [■] (PANEL SW1) INPUT ERROR . 860
FAILURE CODE [DD16LD] MONITOR PANEL MODE SELECTOR SWITCH 1 [◊] (PANEL SW2) INPUT ERROR . 861
FAILURE CODE [DD17LD] THE MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SW3) INPUT CIRCUIT REMAINS CLOSED FOR MORE THAN ONE MINUTE . 862
FAILURE CODE [DD18LD] MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SW4) INPUT ERROR . 863
FAILURE CODE [DD1CLD] SUB-TOTAL SWITCH FAILURE . 864
FAILURE CODE [DDS5L6] DECREASED STEERING OIL PRESSURE 865
FAILURE CODE [DDY0LD] CANCEL SWITCH FAILURE 866
FAILURE CODE [DGE2KX] ENGINE COOLANT TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE 867
FAILURE CODE [DGE3L6] ABNORMAL CONNECTION OF ENGINE COOLANT TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM 868
FAILURE CODE [DGH2KX] HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE 869
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE . 870
FAILURE CODE [DHE4L6] ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE 871
FAILURE CODE [DHPCKX] BOTTOM PRESSURE SENSOR FAILURE . 872
FAILURE CODE [DHPDKX] HEAD PRESSURE SENSOR FAILURE . 874
FAILURE CODE [DKA0KX] LIFT ARM ANGLE SENSOR FAILURE 877
FAILURE CODE [DV00KB] SHORT-CIRCUITED ALARM BUZZER OUTPUT SYSTEM . 878
FAILURE CODE [DY30ME] THE EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE . 880
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) 882
ACTION CODE [MON-2] THE BRAKE OIL PRESSURE WARNING LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (FRONT CIRCUIT) 884
ACTION CODE [MON-3] THE BRAKE OIL PRESSURE WARNING LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT) . 885
ACTION CODE [MON-4] THE AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT ON 886
ACTION CODE [MON-5] THE ENGINE OIL PRESSURE WARNING LAMP DOES NOT LIGHT ON . 888
ACTION CODE [MON-6] THE ENGINE OIL LEVEL WARNING LAMP DOES NOT LIGHT ON 889
ACTION CODE [MON-7] THE ENGINE COOLANT TEMPERATURE WARNING LAMP DOES NOT LIGHT ON 890
ACTION CODE [MON-8] THE RADIATOR COOLANT VOLUME WARNING LAMP DOES NOT LIGHT ON . 891
ACTION CODE [MON-9] THE HYDRAULIC OIL TEMPERATURE WARNING LAMP DOES NOT LIGHT ON . 892
ACTION CODE [MON-10] THE TORQUE CONVERTER OIL TEMPERATURE WARNING LAMP DOES NOT LIGHT ON . 893
ACTION CODE [MON-11] THE STEERING HYDRAULIC WARNING LAMP DOES NOT LIGHT ON . 894
ACTION CODE [MON-12] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [■] (PANEL SW1) 895
ACTION CODE [MON-13] INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 [◊] (PANEL SW2) 896
ACTION CODE [MON-14] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [<] (PANEL SW3) 897
ACTION CODE [MON-15] INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 [>] (PANEL SW4) 898
ACTION CODE [MON-16] DEFECTIVE SUBTOTAL SWITCH . 899
ACTION CODE [MON-17] DEFECTIVE CANCEL SWITCH . 900
ACTION CODE [MON-18] DEFECTIVE BOTTOM PRESSURE SENSOR (HOT SHORT FAULT) 901
ACTION CODE [MON-19] DEFECTIVE HEAD SENSOR . 902
ACTION CODE [MON-20] THE ALARM BUZZER DOES NOT SOUND OR STOP (DISCONNECTION OR SHORT CIRCUIT WITH CHASSIS GROUND IN BUZZER OUTPUT SYSTEM) 903
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) . 905
H-1 THE MACHINE DOES NOT START . 906
H-2 THE LOCK-UP CLUTCH IS NOT RELEASED (THE ENGINE STOPS) (WHEN THE LOCK-UP CLUTCH IS PROVIDED) 908
H-3 a THE TRAVEL SPEED IS SLOW, THE THRUSTING FORCE IS WEAK, THE UPHILL TRAVELING POWER IS WEAK, AND THE GEAR IS NOT SHIFTED . 909
H-3 b THE TORQUE CONVERTER LOCK-UP CLUTCH IS NOT LET IN (IF THE LOCK-UP CLUTCH IS EQUIPPED) 911
H-4 SHOCKS ARE LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR 912
H-5 TIME LAG IS LARGE AT THE TIMES OF STARTING AND SHIFTING GEAR . 914
H-6 THE TORQUE CONVERTER OIL TEMPERATURE IS HIGH . 916
H-7 THE STEERING WHEEL DOES NOT TURN . 917
H-8 THE STEERING WHEEL IS HEAVY 918
H-9 THE STEERING WHEEL FLUCTUATES OR IS STRONGLY SHOCKED . 919
H-10 THE MACHINE STEERS TO ONE SIDE WHEN TRAVELING . 919
H-11 THE RIGHT AND LEFT SWING RADII ARE DIFFERENT 919
H-12 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL . 920
H-13 THE BRAKE IS NOT RELEASED OR IS DRAGGED . 921
H-14 THE BRAKE IS NOT RELEASED OR DRAGGED 922
H-15 THE LIFT ARM DOES NOT RISE 923
H-16 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT 924
H-17 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT . 925
H-18 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET (THE BUCKET RISES IN THE AIR) . 925
H-19 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN 925
H-20 THE LIFT ARM WOBBLES DURING OPERATION . 925
H-21 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “RAISE,” THE LIFT ARM FALLS TEMPORARILY . 926
H-22 THE BUCKET DOES NOT TILT BACK . 927
H-23 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT . 928
H-24 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTING-BACK . 929
H-25 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET . 929
H-26 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN 929
H-27 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO “HOLD”) . 930
H-28 WHEN THE CONTROL LEVER IS SWITCHED FROM “HOLD” TO “TILT,” THE BUCKET FALLS TEMPORARILY 930
H-29 THE CONTROL LEVERS OF LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY 931
H-30 ECSS (TRAVEL DAMPER) DOES NOT WORK, AND THERE IS PITCING AND BOUNCING . 932
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 933
CONNECTOR TYPES AND MOUNTING LOCATIONS . 935
CONNECTOR LAYOUT DRAWING . 944
ELECTRICAL SYSTEM DIAGRAM 950
ACTION CODE [E-1-a] (THE ENGINE DOES NOT START. (STARTING SYSTEM)) . 952
ACTION CODE [E-1-b] (THE ENGINE DOES NOT START. (ENGINE STOP SOLENOID SYSTEM)) . 956
ACTION CODE [E-2] (THE ENGINE DOES NOT STOP) . 958
ACTION CODE [E-3] (PREHEATING IS IMPOSSIBLE OR STAYS OPERATED) . 960
ACTION CODE [E-4] (THE ENGINE POWER MODES CANNOT BE SELECTED) 962
ACTION CODE [E-5] (ALL OF THE BUCKET POSITIONER, LIFT ARM KICK-OUT, AND FLOATING HOLDER DO NOT FUNCTION) . 964
ACTION CODE [E-6] (THE LIFT ARM KICK-OUT DOES NOT FUNCTION OR CANNOT BE RELEASED) 966
ACTION CODE [E-7] (THE BUCKET POSITIONER DOES NOT FUNCTION OR CANNOT BE RELEASED) 968
ACTION CODE [E-8] (THE LIFT ARM FLOATING HOLDER DOES NOT FUNCTION OR CANNOT BE RELEASED) . 970
ACTION CODE [E-9] (THE FRONT WIPER DOES NOT FUNCTION) 971
ACTION CODE [E-10] (THE REAR WIPER DOES NOT FUNCTION) 974
ACTION CODE [E-11] (THE SIDE WIPER DOES NOT FUNCTION (OPT)) 975
ACTION CODE [E-12] (THE WIND WASHER DOES NOT FUNCTION) . 976
ACTION CODE [E-13] (THE HEADLAMP (LO BEAM) DOES NOT LIGHT ON) 979
ACTION CODE [E-14] (THE HEADLAMP (HI BEAM) DOES NOT LIGHT ON) 982
ACTION CODE [E-15] (THE CLEARANCE LAMP DOES NOT LIGHT ON (SMALL LAMP)) . 984
ACTION CODE [E-16] (THE TURN SIGNAL DOES NOT BLINK) 985
ACTION CODE [E-17] (THE HORN DOES NOT SOUND) . 987
ACTION CODE [E-18] (THE AIR CONDITIONER DOES NOT WORK OR DOES NOT STOP) 989
TROUBLESHOOTING OF ENGINE (S MODE) . 993
METHOD OF USING TROUBLESHOOTING CHARTS . 994
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 998
S-2 ENGINE DOES NOT START 999
(1) ENGINE DOES NOT TURN . 999
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) .1000
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) .1001
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) .1002
S-4 ENGINE STOPS DURING OPERATIONS .1003
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 1004
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) .1005
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) .1006
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 1007
S-9 OIL BECOMES CONTAMINATED QUICKLY .1008
S-10 FUEL CONSUMPTION IS EXCESSIVE .1009
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN .1010
S-12 OIL PRESSURE WARNING LAMP LIGHTS UP (DROP IN OIL PRESSURE) 1011
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL) 1012
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 1013
S-15 ABNORMAL NOISE IS MADE 1014
S-16 VIBRATION IS EXCESSIVE 1015
30 DISASSEMBLY AND ASSEMBLY 1017
METHOD OF USING MANUAL .1018
PRECAUTIONS WHEN CARRYING OUT OPERATION 1019
SPECIAL TOOL LIST 1023
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY 1039
REMOVAL 1039
INSTALLATION .1042
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY .1043
REMOVAL 1043
INSTALLATION .1046
REMOVAL AND INSTALLATION OF RADIATOR AND FAN MOTOR ASSEMBLY 1048
REMOVAL 1048
INSTALLATION .1049
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY .1050
REMOVAL 1050
INSTALLATION .1050
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP 1050
REMOVAL 1050
INSTALLATION .1052
REMOVAL AND INSTALLATION OF NOZZLE HOLDER ASSEMBLY .1053
REMOVAL 1053
INSTALLATION .1054
REMOVAL AND INSTALLATION OF FAN AND FAN MOTOR ASSEMBLY .1055
REMOVAL 1055
INSTALLATION .1056
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY .1056
REMOVAL 1056
INSTALLATION .1058
REMOVAL AND INSTALLATION OF PARKING BRAKE DISC PLATE .1058
REMOVAL 1058
INSTALLATION .1060
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY .1061
REMOVAL 1061
INSTALLATION .1064
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY 1065
DISASSEMBLY 1065
ASSEMBLY .1070
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY 1077
DISASSEMBLY 1077
ASSEMBLY .1083
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY .1092
DISASSEMBLY 1092
ASSEMBLY .1094
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (STANDARD SPECIFICATION) .1100
DISASSEMBLY 1100
ASSEMBLY .1101
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION) 1104
DISASSEMBLY 1104
ASSEMBLY .1106
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY .1110
REMOVAL 1110
INSTALLATION .1111
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY 1113
REMOVAL 1113
INSTALLATION .1113
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY 1114
DISASSEMBLY 1114
ASSEMBLY .1117
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY 1124
DISASSEMBLY 1124
ASSEMBLY .1130
REMOVAL AND INSTALLATION OF CENTER HINGE PIN .1144
REMOVAL 1144
INSTALLATION .1148
REMOVAL AND INSTALLATION OF CAB ASSEMBLY .1151
REMOVAL 1151
INSTALLATION .1152
REMOVAL AND INSTALLATION OF CAB AND FLOOR FRAME ASSEMBLY .1152
REMOVAL 1152
INSTALLATION .1154
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS) .1155
REMOVAL 1155
INSTALLATION .1156
REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP ASSEMBLY 1163
REMOVAL 1163
INSTALLATION .1163
REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND FAN PUMP ASSEMBLY .1164
REMOVAL 1164
INSTALLATION .1164
REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE ASSEMBLY .1165
REMOVAL 1165
INSTALLATION .1165
REMOVAL AND INSTALLATION OF TRAVEL DUMPER VALVE ASSEMBLY .1166
REMOVAL 1166
INSTALLATION .1166
REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE ASSEMBLY 1167
REMOVAL 1167
INSTALLATION .1168
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY) .1169
DISASSEMBLY 1169
ASSEMBLY .1172
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY 1177
REMOVAL 1177
ATTACHMENT .1178
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY 1179
REMOVAL 1179
INSTALLATION .1181
REMOVAL AND INSTALLATION OF COUNTER WEIGHT .1183
REMOVAL 1183
INSTALLATION .1183
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 1184
REMOVAL 1184
INSTALLATION .1186
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY 1187
REMOVAL 1187
INSTALLATION .1187
DISASSEMBLY, ASSEMBLY OF OPERATOR’S SEAT ASSEMBLY 1188
DISASSEMBLY 1188
ASSEMBLY .1193
90 OTHERS 1199
POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH) .1200
POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH) 1201
BRAKE OIL CIRCUIT DIAGRAM 1202
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM .1203
ELECTRICAL CIRCUIT DIAGRAM 1/8 (1/4) .1205
ELECTRICAL CIRCUIT DIAGRAM 1/8 (2/4) .1207
ELECTRICAL CIRCUIT DIAGRAM 1/8 (3/4) .1209
ELECTRICAL CIRCUIT DIAGRAM 1/8 (4/4) .1211
ELECTRICAL CIRCUIT DIAGRAM 2/8 (1/4) .1213
ELECTRICAL CIRCUIT DIAGRAM 2/8 (2/4) .1215
ELECTRICAL CIRCUIT DIAGRAM 2/8 (3/4) .1217
ELECTRICAL CIRCUIT DIAGRAM 2/8 (4/4) .1219
ELECTRICAL CIRCUIT DIAGRAM 3/8 .1221
ELECTRICAL CIRCUIT DIAGRAM 4/8 .1223
ELECTRICAL CIRCUIT DIAGRAM 5/8 .1225
ELECTRICAL CIRCUIT DIAGRAM 6/8 .1227
ELECTRICAL CIRCUIT DIAGRAM 7/8 .1229
ELECTRICAL CIRCUIT DIAGRAM 8/8 .1231

DESCRIPTION:

Komatsu WA400-5 Wheel Loader Shop Manual SEBM028007- PDF DOWNLOAD

Machine model     Serial number

• WA400-5                70001 and up

G.B 28/12/24