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Komatsu WA400-5H Wheel Loader Service Repair Manual – PDF Download
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Description
Komatsu WA400-5H Wheel Loader Service Repair Manual
FILE DETAILS:
Komatsu WA400-5H Wheel Loader Service Repair Manual
LANGUAGE:ENGLISH
PAGES:1182
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU WA400-5H WHEEL LOADER SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA400-5H Wheel Loader Service Repair Manual
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
TABLE OF CONTENTS:
Komatsu WA400-5H Wheel Loader Service Repair Manual
WA400-5H PART I................................................................................................................. 1 CONTENTS............................................................................................................................. 2 00 SAFETY / FOREWORD................................................................................................................. 3 SAFETY NOTICE.................................................................................................................... 3 FOREWORD......................................................................................................................... 5 HOW TO READ THE SHOP MANUAL...................................................................................................... 6 HOISTING INSTRUCTIONS............................................................................................................ 7 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER....................................................................... 8 COATING MATERIALS................................................................................................................ 10 STANDARD TIGHTENING TORQUE....................................................................................................... 12 ELECTRIC WIRE CODE............................................................................................................... 15 CONVERSION TABLE................................................................................................................. 16 UNITS............................................................................................................................ 22 01 GENERAL........................................................................................................................... 23 GENERAL ASSEMBLY DRAWING......................................................................................................... 24 SPECIFICATIONS................................................................................................................... 25 WEIGHT TABLE..................................................................................................................... 29 LIST OF LUBRICANT AND COOLANT.................................................................................................... 31 10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...................................................................................... 33 COOLING SYSTEM................................................................................................................... 34 ENGINE MOUNT, TRANSMISSION MOUNT................................................................................................. 35 POWER TRAIN...................................................................................................................... 36 POWER TRAIN SYSTEM DIAGRAM....................................................................................................... 37 DRIVE SHAFT (PROPELLER SHAFT).................................................................................................... 40 TORQUE CONVERTER, TRANSMISSION PIPING............................................................................................ 41 TORQUE CONVERTER................................................................................................................. 42 TRANSMISSION..................................................................................................................... 50 TRANSMISSION CONTROL VALVE....................................................................................................... 66 AXLE............................................................................................................................. 80 DIFFERENTIAL..................................................................................................................... 82 FINAL DRIVE...................................................................................................................... 93 AXLE MOUNTING, CENTER HINGE PIN.................................................................................................. 96 STEERING PIPING.................................................................................................................. 100 STEERING COLUMN, ORBIT-ROLL...................................................................................................... 101 STEERING VALVE................................................................................................................... 102 ORBIT-ROLL VALVE................................................................................................................. 117 STOP VALVE....................................................................................................................... 121 STEERING PUMP, SWITCH PUMP....................................................................................................... 122 EMERGENCY STEERING PUMP (OP)..................................................................................................... 124 EMERGENCY STEERING MOTOR (OP).................................................................................................... 125 STEERING CYLINDER................................................................................................................ 126 JOYSTICK STEERING LEVER (OP)..................................................................................................... 128 STEERING LEVER (OP) (FOR JOYSTICK STEERING LEVER)................................................................................ 129 STEERING SWITCH VALVE (OP) (FOR JOYSTICK STEERING LEVER)......................................................................... 131 BRAKE PIPING..................................................................................................................... 132 BRAKE VALVE...................................................................................................................... 134 CHARGE VALVE..................................................................................................................... 141 ACCUMULATOR (FOR BRAKE).......................................................................................................... 145 BRAKE............................................................................................................................ 147 PARKING BRAKE CONTROL............................................................................................................ 152 PARKING BRAKE.................................................................................................................... 153 PARKING BRAKE SOLENOID VALVE..................................................................................................... 155 PARKING BRAKE EMERGENCY RELEASE VALVE............................................................................................ 157 HYDRAULIC PIPING................................................................................................................. 158 WORK EQUIPMENT CONTROL LEVER..................................................................................................... 161 HYDRAULIC TANK................................................................................................................... 163 TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS............................................................... 165 PPC RELIEF VALVE................................................................................................................. 167 TRAVEL DAMPER VALVE (OP)......................................................................................................... 169 WORK EQUIPMENT CONTROL VALVE..................................................................................................... 171 WORK EQUIPMENT PPC VALVE......................................................................................................... 188 EPC SOLENOID VALVE (OP).......................................................................................................... 194 SHUT OFF VALVE (OP).............................................................................................................. 197 ATTACHMENT PPC VALVE (OP)........................................................................................................ 198 COOLING FAN MOTOR................................................................................................................ 202 COOLING FAN MOTOR DRIVE PUMP..................................................................................................... 207 WORK EQUIPMENT LINKAGE........................................................................................................... 215 BUCKET........................................................................................................................... 217 BUCKET POSITIONER, LIFT ARM KICK-OUT............................................................................................. 218 WORK EQUIPMENT CYLINDER.......................................................................................................... 224 CAB.............................................................................................................................. 225 AIR CONDITIONER (OP)............................................................................................................. 226 MACHINE MONITORING SYSTEM........................................................................................................ 227 MACHINE MONITOR.................................................................................................................. 234 SPEED METER SPECIFICATIONS................................................................................................... 234 LOAD METER SPECIFICATION (OPTION)............................................................................................ 235 TRANSMISSION CONTROL SYSTEM...................................................................................................... 294 TRANSMISSION CONTROLLER.......................................................................................................... 318 WORK EQUIPMENT CONTROL SYSTEM (OP)............................................................................................... 320 WORK EQUIPMENT CONTROLLER........................................................................................................ 336 ELECTRIC TRANSMISSION CONTROL.................................................................................................... 338 KICK DOWN, HOLD SWITCH........................................................................................................... 342 ENGINE STARTING CIRCUIT.......................................................................................................... 343 ENGINE STOP CIRCUIT.............................................................................................................. 345 PREHEATING CIRCUIT............................................................................................................... 346 ENGINE POWER MODE SELECTOR CIRCUIT............................................................................................... 347 PARKING BRAKE CIRCUIT............................................................................................................ 348 SENSORS.......................................................................................................................... 352 20 TESTING AND ADJUSTING............................................................................................................. 363 STANDARD VALUE TABLE FOR ENGINE.................................................................................................. 364 STANDARD VALUE TABLE FOR CHASSIS................................................................................................. 365 MEASURING ENGINE SPEED........................................................................................................... 374 MEASURING EXHAUST COLOR.......................................................................................................... 376 MEASURING EXHAUST TEMPERATURE.................................................................................................... 377 ADJUSTING VALVE CLEARANCE........................................................................................................ 378 MEASURING COMPRESSION PRESSURE................................................................................................... 380 MEASURING BLOW-BY PRESSURE....................................................................................................... 381 MEASURING ENGINE OIL PRESSURE.................................................................................................... 382 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................................... 383 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................................................... 384 ADJUSTING ENGINE SPEED SENSOR.................................................................................................... 385 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................... 386 ADJUSTING ENGINE STOP SOLENOID................................................................................................... 387 ADJUSTING ACCELERATOR PEDAL...................................................................................................... 389 ADJUSTING TRANSMISSION SPEED SENSOR.............................................................................................. 391 TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE................................................................................... 392 DRAWING OF SPECIAL TOOL.......................................................................................................... 396 PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT.......................................................... 397 PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS....................................................................... 398 TESTING AND ADJUSTING STEERING CONTROL........................................................................................... 400 TESTING AND ADJUSTING STEERING OIL PRESSURE...................................................................................... 401 TESTING HYDRAULIC FAN............................................................................................................ 403 MEASURING BRAKE OIL PRESSURE..................................................................................................... 404 TESTING WEAR OF WHEEL BRAKE DISC................................................................................................. 406 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................. 407 TESTING WEAR OF PARKING BRAKE DISC............................................................................................... 408 MANUAL RELEASE METHOD FOR PARKING BRAKE.......................................................................................... 409 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE................................................................................ 410 TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE......................................................................... 412 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.......................................................................... 414 TESTING AND ADJUSTING BUCKET POSITIONER.......................................................................................... 416 TESTING AND ADJUSTING LIFT ARM KICK-OUT.......................................................................................... 417 CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP................................................................................... 418 ADJUSTING MACHINE MONITOR........................................................................................................ 419 TESTING AND ADJUSTING LOAD METER................................................................................................. 422 BLEEDING AIR..................................................................................................................... 423 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................................................ 424 RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT........................................................................... 424 20 TROUBLESHOOTING................................................................................................................... 425 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................... 426 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................ 427 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................................................ 428 CHECKS BEFORE TROUBLESHOOTING.................................................................................................... 436 EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM.................................................................................. 437 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................................................. 438 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS................................................................ 473 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................... 478 20 TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE).......................................................................... 491 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................... 493 CONNECTOR LAYOUT DRAWING......................................................................................................... 502 TRANSMISSION CONTROL SYSTEM DIAGRAM.............................................................................................. 508 ERROR CODE [1500L1].............................................................................................................. 511 ERROR CODE [15SAL1].............................................................................................................. 512 ERROR CODE [15SALH].............................................................................................................. 513 ERROR CODE [15SBL1].............................................................................................................. 514 ERROR CODE [15SBLH].............................................................................................................. 515 ERROR CODE [15SEL1].............................................................................................................. 516 ERROR CODE [15SELH].............................................................................................................. 517 ERROR CODE [15SFL1].............................................................................................................. 518 ERROR CODE [15SFLH].............................................................................................................. 519 ERROR CODE [15SGL1].............................................................................................................. 520 ERROR CODE [15SGLH].............................................................................................................. 521 ERROR CODE [15SHL1].............................................................................................................. 522 ERROR CODE [15SHLH].............................................................................................................. 523 ERROR CODE [15SJL1].............................................................................................................. 524 ERROR CODE [15SJLH].............................................................................................................. 525 ERROR CODE [989F00].............................................................................................................. 526 ERROR CODE [989G00].............................................................................................................. 527 ERROR CODE [B@C7NS].............................................................................................................. 528 ERROR CODE [D150KA].............................................................................................................. 529 ERROR CODE [D150KB].............................................................................................................. 530 ERROR CODE [D160KA].............................................................................................................. 531 ERROR CODE [D160KB].............................................................................................................. 532 ERROR CODE [D191KA].............................................................................................................. 534 ERROR CODE [D191KB].............................................................................................................. 536 ERROR CODE [D192KA].............................................................................................................. 538 ERROR CODE [D192KB].............................................................................................................. 539 ERROR CODE [DAQ0KK].............................................................................................................. 540 ERROR CODE [DAQ2KK].............................................................................................................. 541 ERROR CODE [DAQ9KQ].............................................................................................................. 542 ERROR CODE [DDK3KA].............................................................................................................. 544 ERROR CODE [DDK3KB].............................................................................................................. 546 ERROR CODE [DDK4KA].............................................................................................................. 547 ERROR CODE [DDK4KB].............................................................................................................. 549 ERROR CODE [DDK5LD].............................................................................................................. 551 ERROR CODE [DDK6KA].............................................................................................................. 552 ERROR CODE [DDK6KB].............................................................................................................. 554 ERROR CODE [DDS5KA].............................................................................................................. 556 ERROR CODE [DDS5KB].............................................................................................................. 557 ERROR CODE [DDT0L4].............................................................................................................. 558 ERROR CODE [DDT4LD].............................................................................................................. 560 ERROR CODE [DDW9LD].............................................................................................................. 561 ERROR CODE [DDWLLD].............................................................................................................. 562 ERROR CODE [DF10KA].............................................................................................................. 564 ERROR CODE [DF10KB].............................................................................................................. 566 ERROR CODE [DGF1KX].............................................................................................................. 568 ERROR CODE [DGR2KA].............................................................................................................. 569 ERROR CODE [DGR2KB].............................................................................................................. 570 ERROR CODE [DHT1KX].............................................................................................................. 571 ERROR CODE [DLE2KA].............................................................................................................. 572 ERROR CODE [DLE2LC].............................................................................................................. 573 ERROR CODE [DLT3KA].............................................................................................................. 574 ERROR CODE [DT20KB].............................................................................................................. 575 ERROR CODE [DW7BKA].............................................................................................................. 576 ERROR CODE [DW7BKB].............................................................................................................. 577 ERROR CODE [DW7CKA].............................................................................................................. 578 ERROR CODE [DW7CKB].............................................................................................................. 579 ERROR CODE [DX16KA].............................................................................................................. 580 ERROR CODE [DX16KB].............................................................................................................. 581 ERROR CODE [DXH1KA].............................................................................................................. 582 ERROR CODE [DXH1KB].............................................................................................................. 583 ERROR CODE [DXH4KA].............................................................................................................. 584 ERROR CODE [DXH4KB].............................................................................................................. 585 ERROR CODE [DXH5KA].............................................................................................................. 586 ERROR CODE [DXH5KB].............................................................................................................. 587 ERROR CODE [DXH6KA].............................................................................................................. 588 ERROR CODE [DXH6KB].............................................................................................................. 589 ERROR CODE [DXH7KA].............................................................................................................. 590 ERROR CODE [DXH7KB].............................................................................................................. 591 ERROR CODE [DXH8KA].............................................................................................................. 592 ERROR CODE [DXH8KB].............................................................................................................. 593 ERROR CODE [DXHHKA].............................................................................................................. 594 ERROR CODE [DXHHKB].............................................................................................................. 595 ERROR CODE [DY30MA].............................................................................................................. 596 ERROR CODE [DY30MC].............................................................................................................. 598 ACTION CODE [TM-1]............................................................................................................... 600 ACTION CODE [TM-2]............................................................................................................... 601 ACTION CODE [TM-3]............................................................................................................... 602 ACTION CODE [TM-4]............................................................................................................... 604 ACTION CODE [TM-5]............................................................................................................... 606 ACTION CODE [TM-6]............................................................................................................... 608 ACTION CODE [TM-7]............................................................................................................... 609 ACTION CODE [TM-8]............................................................................................................... 610 ACTION CODE [TM-9]............................................................................................................... 611 ACTION CODE [TM-10-a]............................................................................................................ 612 ACTION CODE [TM-10-b]............................................................................................................ 614 ACTION CODE [TM-11].............................................................................................................. 616 ACTION CODE [TM-12].............................................................................................................. 618 ACTION CODE [TM-13].............................................................................................................. 619 ACTION CODE [TM-14].............................................................................................................. 620 ACTION CODE [TM-15].............................................................................................................. 621 ACTION CODE [TM-16].............................................................................................................. 622 ACTION CODE [TM-17].............................................................................................................. 623 ACTION CODE [TM-18].............................................................................................................. 624 ACTION CODE [TM-19].............................................................................................................. 625 ACTION CODE [TM-20].............................................................................................................. 626 ACTION CODE [TM-21].............................................................................................................. 627 ACTION CODE [TM-22].............................................................................................................. 628 ACTION CODE [TM-23].............................................................................................................. 629 ACTION CODE [TM-24].............................................................................................................. 630 ACTION CODE [TM-25].............................................................................................................. 631 ACTION CODE [TM-26].............................................................................................................. 632 ACTION CODE [TM-27].............................................................................................................. 633 ACTION CODE [TM-28].............................................................................................................. 634 ACTION CODE [TM-29].............................................................................................................. 635 20 TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)....................................................................... 637 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................... 639 CONNECTOR LAYOUT DRAWING......................................................................................................... 648 WORK EQUIPMENT CONTROL SYSTEM DIAGRAM............................................................................................ 654 ERROR CODE [D193KA].............................................................................................................. 657 ERROR CODE [D193KB].............................................................................................................. 658 ERROR CODE [DB90KK].............................................................................................................. 659 ERROR CODE [DB92KK].............................................................................................................. 660 ERROR CODE [DB95KX].............................................................................................................. 662 ERROR CODE [DD1ALD].............................................................................................................. 664 ERROR CODE [DD1BLD].............................................................................................................. 665 ERROR CODE [DFAOKM].............................................................................................................. 666 ERROR CODE [DK59KA].............................................................................................................. 667 ERROR CODE [DK59KY].............................................................................................................. 668 ERROR CODE [DK59L8].............................................................................................................. 669 ERROR CODE [DK5AKA].............................................................................................................. 670 ERROR CODE [DK5AKY].............................................................................................................. 671 ERROR CODE [DK5BKA].............................................................................................................. 672 ERROR CODE [DK5BKY].............................................................................................................. 673 ERROR CODE [DK5BL8].............................................................................................................. 674 ERROR CODE [DK5CKA].............................................................................................................. 675 ERROR CODE [DK5CKY].............................................................................................................. 676 ERROR CODE [DK5DKA].............................................................................................................. 677 ERROR CODE [DK5DKY].............................................................................................................. 678 ERROR CODE [DK5DL8].............................................................................................................. 679 ERROR CODE [DK5EKA].............................................................................................................. 680 ERROR CODE [DK5EKY].............................................................................................................. 681 ERROR CODE [DK5FKA].............................................................................................................. 682 ERROR CODE [DK5FKY].............................................................................................................. 683 ERROR CODE [DK5FKM].............................................................................................................. 684 ERROR CODE [DK5FL8].............................................................................................................. 685 ERROR CODE [DK5GKA].............................................................................................................. 686 ERROR CODE [DK5GKY].............................................................................................................. 687 ERROR CODE [DKAOKA].............................................................................................................. 688 ERROR CODE [DKAOKY].............................................................................................................. 689 ERROR CODE [DLE2LC].............................................................................................................. 690 ERROR CODE [DLT3LC].............................................................................................................. 691 ERROR CODE [DUM1KB].............................................................................................................. 692 ERROR CODE [DUM2KB].............................................................................................................. 693 ERROR CODE [DW4PKA].............................................................................................................. 694 ERROR CODE [DW4PKB].............................................................................................................. 695 ERROR CODE [DW4QKA].............................................................................................................. 696 ERROR CODE [DW4QKB].............................................................................................................. 697 ERROR CODE [DW4RKA].............................................................................................................. 698 ERROR CODE [DW4RKB].............................................................................................................. 699 ERROR CODE [DW4SKA].............................................................................................................. 700 ERROR CODE [DW4SKB].............................................................................................................. 701 ERROR CODE [DWM1KA].............................................................................................................. 702 ERROR CODE [DWM1KB].............................................................................................................. 703 ERROR CODE [DWN6KA].............................................................................................................. 704 ERROR CODE [DWN6KB].............................................................................................................. 705 ERROR CODE [DWN7KA].............................................................................................................. 706 ERROR CODE [DWN7KB].............................................................................................................. 707 ERROR CODE [DWN8KA].............................................................................................................. 708 ERROR CODE [DWN8KB].............................................................................................................. 709 ERROR CODE [DXHJKA].............................................................................................................. 710 ERROR CODE [DXHJKB].............................................................................................................. 711 ERROR CODE [DXHKKA].............................................................................................................. 712 ERROR CODE [DXHKKB].............................................................................................................. 713 ERROR CODE: [DXHLKA]............................................................................................................. 714 ERROR CODE: [DXHLKB]............................................................................................................. 715 ERROR CODE: [DXHMKA]............................................................................................................. 716 ERROR CODE: [DXHMKB]............................................................................................................. 717 ACTION CODE: [WRK-1]............................................................................................................. 718 ACTION CODE: [WRK-2]............................................................................................................. 719 ACTION CODE: [WRK-3]............................................................................................................. 720 ACTION CODE: [WRK-4]............................................................................................................. 722 ACTION CODE: [WRK-5]............................................................................................................. 724 ACTION CODE: [WRK-6]............................................................................................................. 726 ACTION CODE: [WRK-7]............................................................................................................. 728 ACTION CODE: [WRK-8]............................................................................................................. 729 ACTION CODE: [WRK-9]............................................................................................................. 730 ACTION CODE: [WRK-10]............................................................................................................ 732 ACTION CODE: [WRK-11]............................................................................................................ 734 ACTION CODE: [WRK-12]............................................................................................................ 735 ACTION CODE: [WRK-13]............................................................................................................ 736 ACTION CODE: [WRK-14]............................................................................................................ 737 ACTION CODE: [WRK-15]............................................................................................................ 738 ACTION CODE: [WRK-16]............................................................................................................ 739 ACTION CODE: [WRK-17]............................................................................................................ 740 ACTION CODE: [WRK-18]............................................................................................................ 741 ACTION CODE: [WRK-19]............................................................................................................ 742 ACTION CODE: [WRK-20]............................................................................................................ 743 ACTION CODE: [WRK-21]............................................................................................................ 744 ACTION CODE: [WRK-22]............................................................................................................ 745 ACTION CODE: [WRK-23]............................................................................................................ 746 ACTION CODE: [WRK-24]............................................................................................................ 747 ACTION CODE: [WRK-25]............................................................................................................ 748 ACTION CODE: [WRK-26]............................................................................................................ 750 ACTION CODE: [WRK-27]............................................................................................................ 752 ACTION CODE: [WRK-28]............................................................................................................ 754 20 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)...................................................................................... 757 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................... 759 CONNECTOR LAYOUT DRAWING......................................................................................................... 768 MONITOR SYSTEM DIAGRAM........................................................................................................... 774 ERROR CODE [2F00KM].............................................................................................................. 778 ERROR CODE [2G42ZG].............................................................................................................. 780 ERROR CODE [2G43ZG].............................................................................................................. 781 ERROR CODE [AA1ANX].............................................................................................................. 782 ERROR CODE [AB00L6].............................................................................................................. 784 ERROR CODE [AB00MA].............................................................................................................. 785 ERROR CODE [B@BAZG].............................................................................................................. 786 ERROR CODE [B@BAZK].............................................................................................................. 787 ERROR CODE [B@BCNS].............................................................................................................. 788 ERROR CODE [B@BCZK].............................................................................................................. 789 ERROR CODE [B@HANS].............................................................................................................. 790 ERROR CODE [B@CENS].............................................................................................................. 791 ERROR CODE [D182KZ].............................................................................................................. 792 ERROR CODE [D5ZHL6].............................................................................................................. 794 ERROR CODE [DA80L4].............................................................................................................. 795 ERROR CODE [DAF3KK].............................................................................................................. 796 ERROR CODE [DAF5KP].............................................................................................................. 798 ERROR CODE [DAF6KP].............................................................................................................. 800 ERROR CODE [DAFBKM].............................................................................................................. 802 ERROR CODE [DAFSKQ].............................................................................................................. 803 ERROR CODE [DAQSKR].............................................................................................................. 804 ERROR CODE [DB2SKR].............................................................................................................. 805 ERROR CODE [DBQSKR].............................................................................................................. 806 ERROR CODE [DB9SKR].............................................................................................................. 807 ERROR CODE [DD15LD].............................................................................................................. 808 ERROR CODE [DD16LD].............................................................................................................. 809 ERROR CODE [DD17LD].............................................................................................................. 810 ERROR CODE [DD17LD].............................................................................................................. 811 ERROR CODE [DD1CLD].............................................................................................................. 812 ERROR CODE [DDK3KM].............................................................................................................. 813 ERROR CODE [DDK4KM].............................................................................................................. 814 ERROR CODE [DDK6KM].............................................................................................................. 815 ERROR CODE [DDS5L6].............................................................................................................. 816 ERROR CODE [DDY0LD].............................................................................................................. 817 ERROR CODE [DGE2KX].............................................................................................................. 818 ERROR CODE [DGE3L6].............................................................................................................. 819 ERROR CODE [DGH2KX].............................................................................................................. 820 ERROR CODE [DGT1KX].............................................................................................................. 821 ERROR CODE [DHE4L6].............................................................................................................. 822 ERROR CODE [DHPCKX].............................................................................................................. 824 ERROR CODE [DHPDKX].............................................................................................................. 826 ERROR CODE [DKA0KX].............................................................................................................. 828 ERROR CODE [DV00KB].............................................................................................................. 829 ERROR CODE [DY30ME].............................................................................................................. 830 ACTION CODE [MON-1].............................................................................................................. 832 ACTION CODE [MON-2].............................................................................................................. 834 ACTION CODE [MON-3].............................................................................................................. 835 ACTION CODE [MON-4].............................................................................................................. 836 ACTION CODE [MON-5].............................................................................................................. 838 ACTION CODE [MON-6].............................................................................................................. 839 ACTION CODE [MON-7].............................................................................................................. 840 ACTION CODE [MON-8].............................................................................................................. 841 ACTION CODE [MON-10]............................................................................................................. 843 ACTION CODE [MON-11]............................................................................................................. 844 ACTION CODE [MON-12]............................................................................................................. 845 ACTION CODE [MON-13]............................................................................................................. 846 ACTION CODE [MON-14]............................................................................................................. 847 ACTION CODE [MON-15]............................................................................................................. 848 ACTION CODE [MON-16]............................................................................................................. 849 ACTION CODE [MON-17]............................................................................................................. 850 ACTION CODE [MON-18]............................................................................................................. 851 ACTION CODE [MON-19]............................................................................................................. 852 ACTION CODE [MON-20]............................................................................................................. 853 20 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).......................................................................... 855 H-1 The machine does not start................................................................................................... 856 H-2 The lock-up clutch is not released........................................................................................... 858 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.... 859 H-3 b. The torque converter lock-up clutch is not let in (If the lock-up clutch is equipped)..................................... 861 H-4 Shocks are large at the times of starting and shifting gear.................................................................. 862 H-5 Time lag is large at the times of starting and shifting gear................................................................. 864 H-6 The torque converter oil temperature is high................................................................................. 866 H-7 Steering wheel does not turn................................................................................................. 866 H-8 Steering does not turn [machine with joystick]............................................................................... 868 H-9 Turning, response of steering is poor........................................................................................ 869 H-10 Steering is heavy........................................................................................................... 870 H-11 Steering wheel shakes or jerks.............................................................................................. 871 H-12 The brake does not work or does not work well............................................................................... 872 H-13 The brake is not released or is dragged..................................................................................... 873 H-14 The brake is not released or dragged........................................................................................ 874 H-15 The lift arm does not rise.................................................................................................. 875 H-16 The lift arm moves slowly or the lift arm rising force is insufficient...................................................... 876 H-17 When rising, the lift arm comes to move slowly at specific height........................................................... 877 H-18 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)............................................. 877 H-19 Hydraulic drifts of the boom occur often.................................................................................... 877 H-20 The lift arm wobbles during operation....................................................................................... 877 H-21 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily................................... 878 H-22 The bucket does not tilt back............................................................................................... 879 H-23 The bucket moves slowly or the tilting-back force is insufficient........................................................... 880 H-24 The bucket comes to operate slowly in he midst of tilting-back.............................................................. 881 H-25 The bucket cylinder cannot hold down the bucket............................................................................. 881 H-26 Hydraulic drifts of the bucket occur often.................................................................................. 881 H-27 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD")..................................... 882 H-28 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily...................................... 882 H-29 The control levers of lift arm and bucket do not move smoothly and heavy.................................................... 883 20 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..................................................................................... 885 CONNECTOR TYPES AND MOUNTING LOCATIONS........................................................................................... 887 CONNECTOR LAYOUT DRAWING......................................................................................................... 896 ELECTRICAL SYSTEM DIAGRAM........................................................................................................ 902 ACTION CODE: [E-1-a]............................................................................................................. 904 ACTION CODE: [E-1-b]............................................................................................................. 908 ACTION CODE: [E-2]............................................................................................................... 910 ACTION CODE: [E-3]............................................................................................................... 912 ACTION CODE: [E-4]............................................................................................................... 914 ACTION CODE: [E-5]............................................................................................................... 916 ACTION CODE: [E-6]............................................................................................................... 918 ACTION CODE: [E-7]............................................................................................................... 920 ACTION CODE: [E-8]............................................................................................................... 923 ACTION CODE: [E-9]............................................................................................................... 924 ACTION CODE: [E-10].............................................................................................................. 927 ACTION CODE: [E-11].............................................................................................................. 928 ACTION CODE: [E-12].............................................................................................................. 929 ACTION CODE: [E-13].............................................................................................................. 932 ACTION CODE: [E-14].............................................................................................................. 935 ACTION CODE: [E-15].............................................................................................................. 937 ACTION CODE: [E-16].............................................................................................................. 938 ACTION CODE: [E-17].............................................................................................................. 940 ACTION CODE: [E-18].............................................................................................................. 942 WA400-5H PART II................................................................................................................ 945 DISASSEMBLY AND ASSEMBLY............................................................................................................. 949 Method of using manual........................................................................................................... 951 Precautions when carrying out operation.......................................................................................... 952 Engine assembly.................................................................................................................. 956 Removal...................................................................................................................... 956 Installation................................................................................................................. 960 Cylinder head assembly........................................................................................................... 961 Special tool................................................................................................................. 961 Removal...................................................................................................................... 961 Installation................................................................................................................. 966 Radiator and fan motor assembly.................................................................................................. 969 Removal...................................................................................................................... 969 Installation................................................................................................................. 970 Aftercooler assembly............................................................................................................. 971 Removal...................................................................................................................... 971 Installation................................................................................................................. 971 Fuel injection pump.............................................................................................................. 972 Special tool................................................................................................................. 972 Removal...................................................................................................................... 972 Installation................................................................................................................. 974 Nozzle holder assembly........................................................................................................... 977 Removal...................................................................................................................... 977 Installation................................................................................................................. 979 Fan and fan motor assembly....................................................................................................... 980 Removal...................................................................................................................... 980 Installation................................................................................................................. 981 Fuel tank assembly............................................................................................................... 982 Removal...................................................................................................................... 982 Installation................................................................................................................. 984 Parking brake disc plate......................................................................................................... 985 Special tool................................................................................................................. 985 Removal...................................................................................................................... 985 Installation................................................................................................................. 988 Sketch of special tool....................................................................................................... 989 K1 Bracket............................................................................................................... 989 Torque converter and transmission assembly....................................................................................... 990 Removal...................................................................................................................... 990 Installation................................................................................................................. 995 Bleeding air of brake circuit................................................................................................ 995 Transmission assembly............................................................................................................ 996 Special tool................................................................................................................. 996 Disassembly.................................................................................................................. 996 Assembly.....................................................................................................................1003 Sketches of special tools....................................................................................................1012 F1 Lifting tool..........................................................................................................1012 F4 Bracket...............................................................................................................1012 Transmission clutch pack assembly................................................................................................1013 Special tools................................................................................................................1013 Disassembly..................................................................................................................1013 Disassembly of forward and reverse clutch packs..............................................................................1013 [Forward clutch side]....................................................................................................1013 [Reverse clutch side]....................................................................................................1015 Disassembly of 1st and 4th clutch pack.......................................................................................1016 [1st clutch side]........................................................................................................1016 [4th clutch side]........................................................................................................1018 Disassembly of 2nd and 3rd clutch pack.......................................................................................1019 [3rd clutch side]........................................................................................................1019 [2nd clutch side]........................................................................................................1021 Assembly of the forward and reverse clutch packs.............................................................................1022 [Reverse clutch side]....................................................................................................1022 [Forward clutch side]....................................................................................................1024 Assembly of 1st and 4th clutch pack..........................................................................................1026 [4th clutch side]........................................................................................................1026 [1st clutch side]........................................................................................................1028 Assembly of 2nd and 3rd clutch pack..........................................................................................1031 [2nd clutch side]........................................................................................................1031 [3rd clutch side]........................................................................................................1033 Parking brake assembly...........................................................................................................1035 Special tools................................................................................................................1035 Disassembly..................................................................................................................1035 Assembly.....................................................................................................................1038 Special tool simplified drawings.................................................................................................1044 F10 Push tool................................................................................................................1044 H1 Bracket...................................................................................................................1044 H4 Spacer....................................................................................................................1045 H3 Push tool.................................................................................................................1045 H6 Push tool.................................................................................................................1046 H5 Push tool.................................................................................................................1046 H9 Spacer....................................................................................................................1047 H8 Push tool.................................................................................................................1047 Torque converter assembly (standard specification)...............................................................................1048 Special tools................................................................................................................1048 Disassembly..................................................................................................................1048 Assembly.....................................................................................................................1051 Torque converter assembly (lock-up specification)................................................................................1054 Special tools................................................................................................................1054 Disassembly..................................................................................................................1054 Assembly.....................................................................................................................1058 Rear axle assembly...............................................................................................................1062 Removal......................................................................................................................1062 Installation.................................................................................................................1065 Front axle assembly..............................................................................................................1066 Removal......................................................................................................................1066 Installation.................................................................................................................1067 Axle housing assembly............................................................................................................1068 Special tools................................................................................................................1068 Disassembly..................................................................................................................1068 Assembly of rear axle housing................................................................................................1073 Assembly of front axle housing...............................................................................................1079 Special tool simplified drawings.................................................................................................1084 J1 Spacer (for rear axle housing)............................................................................................1084 J2 Push tool (for rear axle housing).........................................................................................1084 J3 Push tool (for rear axle housing).........................................................................................1085 J1 Push tool (for rear axle housing).........................................................................................1085 J4-1 Push tool (for front axle housing)......................................................................................1086 J4-2 Spacer (for front axle housing).........................................................................................1086 J6-1 Support (for front axle housing)........................................................................................1087 Differential assembly............................................................................................................1088 Special tools................................................................................................................1088 Disassembly..................................................................................................................1088 Assembly.....................................................................................................................1094 Special tool illustrations.......................................................................................................1106 D3-2 Spacer (for rear differential)..........................................................................................1106 D2-1, D3-1 Push tool (for rear differential).................................................................................1106 D5-1 Push tool (for rear differential).......................................................................................1107 D5-2 Push tool (for rear differential).......................................................................................1107 D4 Push tool (for rear differential).........................................................................................1108 D1-3 Plate (for front differential)..........................................................................................1108 D2-1, D3-1 Push tool (for front differential)................................................................................1109 D3-2 Spacer (for front differential).........................................................................................1109 D4 Push tool (for front differential)........................................................................................1110 D5-1 Push tool (for front differential)......................................................................................1110 Center hinge pin.................................................................................................................1111 Special tools................................................................................................................1111 Removal......................................................................................................................1111 Installation.................................................................................................................1117 Cab assembly.....................................................................................................................1121 Removal......................................................................................................................1121 Installation.................................................................................................................1123 Cab and floor frame assembly.....................................................................................................1124 Removal......................................................................................................................1124 Installation.................................................................................................................1127 Transmission, work equipment, and PPC pump assembly..............................................................................1128 Removal......................................................................................................................1128 Installation.................................................................................................................1128 Steering, switching, and fan pump assembly.......................................................................................1129 Removal......................................................................................................................1129 Installation.................................................................................................................1129 Steering demand valve assembly...................................................................................................1130 Removal......................................................................................................................1130 Installation.................................................................................................................1130 E.C.S.S. valve assembly..........................................................................................................1131 Removal......................................................................................................................1131 Installation.................................................................................................................1131 Work equipment valve assembly....................................................................................................1132 Removal......................................................................................................................1132 Installation.................................................................................................................1133 Hydraulic cylinder assembly (steering, lift, and bucket cylinder assembly).......................................................1134 Special tools................................................................................................................1134 Disassembly..................................................................................................................1135 Assembly.....................................................................................................................1139 Hydraulic tank assembly..........................................................................................................1144 Removal......................................................................................................................1144 Attachment...................................................................................................................1145 Work equipment assembly..........................................................................................................1146 Removal......................................................................................................................1146 Installation.................................................................................................................1150 Counter weight...................................................................................................................1152 Removal......................................................................................................................1152 Installation.................................................................................................................1152 Air conditioner unit assembly....................................................................................................1153 Removal......................................................................................................................1153 Installation.................................................................................................................1156 Air conditioner compressor assembly..............................................................................................1157 Removal......................................................................................................................1157 Installation.................................................................................................................1157 90 OTHERS............................................................................................................................1159 POWER TRAIN OIL CIRCUIT DIAGRAM (WITHOUT TORQUE CONVERTER LOCKUP CLUTCH).........................................................1161 POWER TRAIN OIL CIRCUIT DIAGRAM (WITH TORQUE CONVERTER LOCKUP CLUTCH)............................................................1163 BRAKE OIL CIRCUIT DIAGRAM........................................................................................................1165 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.........................................................................................1167 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER).....................................................1168 ELECTRIC CIRCUIT DIAGRAM (1/8)...................................................................................................1169 ELECTRIC CIRCUIT DIAGRAM (1/8)...................................................................................................1170 ELECTRIC CIRCUIT DIAGRAM (1/8)...................................................................................................1171 ELECTRIC CIRCUIT DIAGRAM (1/8)...................................................................................................1172 ELECTRIC CIRCUIT DIAGRAM (2/8)...................................................................................................1173 ELECTRIC CIRCUIT DIAGRAM (2/8)...................................................................................................1174 ELECTRIC CIRCUIT DIAGRAM (2/8)...................................................................................................1175 ELECTRIC CIRCUIT DIAGRAM (2/8)...................................................................................................1176 ELECTRIC CIRCUIT DIAGRAM (3/8)...................................................................................................1177 ELECTRIC CIRCUIT DIAGRAM (4/8)...................................................................................................1178 ELECTRIC CIRCUIT DIAGRAM (5/8)...................................................................................................1179 ELECTRIC CIRCUIT DIAGRAM (6/8)...................................................................................................1180 ELECTRIC CIRCUIT DIAGRAM (7/8)...................................................................................................1181 ELECTRIC CIRCUIT DIAGRAM (8/8)...................................................................................................1182
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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Bronson Forrest –