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Komatsu WA400-5L WHEEL LOADER SERVICE REPAIR MANUAL (SN: A40001 & up) – PDF Download
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- Komatsu WA400-5L WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER: A40001 & up
- PUBLICATION NUMBER:CEBM010002
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Description
Komatsu WA400-5L WHEEL LOADER SERVICE REPAIR MANUAL (SN: A40001 & up)
KOMATSU WA400-5L WHEEL LOADER SERVICE REPAIR MANUAL (SN: A40001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu WA400-5L WHEEL LOADER SERVICE REPAIR MANUAL (SN: A40001 & up)
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - 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. - TESTING, ADJUSTING AND TROUBLESHOOTING
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” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA400-5L WHEEL LOADER SERVICE REPAIR MANUAL (SN: A40001 & up)
COVER............................................................................................................... 1 FOREWORD............................................................................................................ 2 CONTENTS........................................................................................................ 2 SAFETY.......................................................................................................... 13 SAFETY NOTICE............................................................................................... 13 GENERAL......................................................................................................... 15 HOW TO READ THE SHOP MANUAL..................................................................................... 16 HOISTING INSTRUCTIONS........................................................................................... 17 COATING MATERIALS............................................................................................... 18 STANDARD TIGHTENING TORQUE...................................................................................... 20 ELECTRIC WIRE CODE.............................................................................................. 22 CONVERSION TABLES............................................................................................... 23 01 GENERAL.......................................................................................................... 29 SPECIFICATIONS.................................................................................................. 30 WEIGHT TABLE.................................................................................................... 34 FUEL, COOLANT AND LUBRICANTS.................................................................................... 36 GENERAL ASSEMBLY DRAWING........................................................................................ 38 10 STRUCTURE AND FUNCTION........................................................................................... 39 COOLING SYSTEM.................................................................................................. 45 SPECIFICATIONS.............................................................................................. 45 ENGINE MOUNT, TRANSMISSION MOUNT................................................................................ 46 POWER TRAIN..................................................................................................... 47 POWER TRAIN SYSTEM DIAGRAM...................................................................................... 48 WITHOUT TORQUE CONVERTER LOCKUP CLUTCH...................................................................... 48 WITH TORQUE CONVERTER LOCK-UP CLUTCH........................................................................ 49 OUTLINE..................................................................................................... 51 DRIVE SHAFT (PROPELLER SHAFT)................................................................................... 52 OUTLINE..................................................................................................... 52 TORQUE CONVERTER, TRANSMISSION PIPING........................................................................... 53 TORQUE CONVERTER................................................................................................ 54 WITHOUT LOCK-UP CLUTCH...................................................................................... 54 PATH OF POWER TRANSMISSION.................................................................................. 56 POWER FLOW.............................................................................................. 56 OIL FLOW................................................................................................ 56 WITH LOCK-UP CLUTCH......................................................................................... 57 PATH OF POWER TRANSMISSION.................................................................................. 60 LOCK-UP CLUTCH DISENGAGED............................................................................... 60 LOCK-UP CLUTCH ENGAGED.................................................................................. 60 OIL FLOW................................................................................................ 61 TRANSMISSION.................................................................................................... 62 OUTLINE..................................................................................................... 66 F AND R CLUTCHES: WITHOUT LOCK-UP CLUTCH.................................................................... 67 F AND R CLUTCHES: WITH LOCK-UP CLUTCH....................................................................... 68 1ST AND 4TH CLUTCH.......................................................................................... 69 2ND AND 3RD CLUTCH.......................................................................................... 70 CLUTCH OPERATION............................................................................................ 71 CLUTCH ENGAGED.......................................................................................... 71 CLUTCH DISENGAGED....................................................................................... 71 FORWARD 1ST................................................................................................. 72 OPERATION............................................................................................... 72 FORWARD 2ND................................................................................................. 73 OPERATION............................................................................................... 73 FORWARD 3RD................................................................................................. 74 OPERATION............................................................................................... 74 FORWARD 4TH................................................................................................. 75 OPERATION............................................................................................... 75 REVERSE 1ST................................................................................................. 76 OPERATION............................................................................................... 76 TRANSMISSION CONTROL VALVE...................................................................................... 77 WITHOUT LOCK-UP CLUTCH...................................................................................... 77 OUTLINE................................................................................................. 78 WITH LOCK-UP CLUTCH......................................................................................... 79 OUTLINE................................................................................................. 80 ELECTRONIC CONTROL MODULATION VALVE (ECMV).................................................................. 81 ECMV FOR SPEED CLUTCH....................................................................................... 82 OUTLINE................................................................................................. 82 ECMV AND PROPORTIONAL SOLENOID.......................................................................... 82 ECMV AND FILL SWITCH.................................................................................... 82 ECMV ACTUATION.......................................................................................... 83 ECMV FOR LOCK-UP CLUTCH..................................................................................... 85 OUTLINE................................................................................................. 85 OPERATION WHEN TRAVELING IN TORQUE CONVERTER DRIVE...................................................... 85 WHEN TRAVELING IN DIRECT DRIVE (CHANGING FROM TORQUE CONVERTER DRIVE ? DIRECT DRIVE)................... 86 MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE.................................................................. 87 OUTLINE................................................................................................. 89 OPERATION............................................................................................... 89 FLOW VALVE.................................................................................................. 90 OPERATION............................................................................................... 90 AXLE............................................................................................................ 91 FRONT AXLE.................................................................................................. 91 REAR AXLE................................................................................................... 92 DIFFERENTIAL.................................................................................................... 93 FRONT DIFFERENTIAL.......................................................................................... 93 REAR DIFFERENTIAL........................................................................................... 95 OUTLINE................................................................................................. 97 LIMITED SLIP DIFFERENTIAL................................................................................... 98 LIMITED SLIP DIFFERENTIAL OPERATION..................................................................... 102 FINAL DRIVE..................................................................................................... 104 OUTLINE..................................................................................................... 106 AXLE MOUNTING, CENTER HINGE PIN................................................................................. 107 OUTLINE..................................................................................................... 107 STEERING PIPING................................................................................................. 111 STEERING COLUMN, ORBIT ROLL..................................................................................... 112 STEERING VALVE.................................................................................................. 113 OVERLOAD RELIEF VALVE....................................................................................... 115 FUNCTION................................................................................................ 115 OPERATION............................................................................................... 115 STEERING RELIEF VALVE....................................................................................... 117 FUNCTION................................................................................................ 117 STEERING RELIEF VALVE OPERATION......................................................................... 118 DEMAND VALVE OPERATION.................................................................................. 119 FLOW AMP........................................................................................................ 122 STEERING VALVE OPERATION........................................................................................ 126 NEUTRAL..................................................................................................... 126 TURNING RIGHT............................................................................................... 127 TURNING LEFT................................................................................................ 128 ORBIT-ROLL VALVE................................................................................................ 129 OUTLINE..................................................................................................... 130 STRUCTURE................................................................................................... 130 CONNECTION BETWEEN THE HAND PUMP AND SLEEVE..................................................................... 131 STOP VALVE...................................................................................................... 133 EMERGENCY STEERING PUMP......................................................................................... 134 FUNCTION.................................................................................................... 134 EMERGENCY STEERING MOTOR........................................................................................ 135 FUNCTION.................................................................................................... 135 STEERING CYLINDER............................................................................................... 136 JOYSTICK STEERING............................................................................................... 138 JOYSTICK PPC VALVE.......................................................................................... 139 FUNCTION................................................................................................ 139 STEERING SWITCH VALVE........................................................................................... 141 BRAKE PIPING.................................................................................................... 142 BRAKE VALVE..................................................................................................... 144 BRAKE VALVE - LEFT.......................................................................................... 144 BRAKE VALVE - RIGHT......................................................................................... 146 OUTLINE................................................................................................. 148 OPERATION............................................................................................... 148 CHARGE VALVE.................................................................................................... 151 FUNCTION.................................................................................................... 152 OPERATION................................................................................................... 153 PPC RELIEF VALVE............................................................................................ 155 OUTLINE................................................................................................. 155 OPERATION............................................................................................... 155 ACCUMULATOR - BRAKE............................................................................................. 156 FUNCTION.................................................................................................... 156 SPECIFICATIONS.......................................................................................... 156 FUNCTION.................................................................................................... 157 SPECIFICATIONS.......................................................................................... 157 BRAKE........................................................................................................... 158 FRONT....................................................................................................... 158 OUTLINE................................................................................................. 159 REAR........................................................................................................ 160 OUTLINE................................................................................................. 161 OPERATION................................................................................................... 162 PARKING BRAKE CONTROL........................................................................................... 163 OUTLINE..................................................................................................... 163 PARKING BRAKE................................................................................................... 164 OUTLINE..................................................................................................... 164 PARKING BRAKE SOLENOID VALVE................................................................................ 166 OPERATION................................................................................................... 167 PARKING BRAKE EMERGENCY RELEASE VALVE....................................................................... 168 OUTLINE................................................................................................. 168 HYDRAULIC PIPING................................................................................................ 169 OUTLINE..................................................................................................... 172 WORK EQUIPMENT CONTROL LEVER.................................................................................... 173 FOR PPC VALVE............................................................................................... 173 HYDRAULIC TANK.................................................................................................. 174 BREATHER.................................................................................................... 175 HYDRAULIC PUMPS................................................................................................. 176 STEERING PUMP, SWITCH PUMP.................................................................................. 176 OUTLINE................................................................................................. 176 TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS.......................................... 178 OUTLINE................................................................................................. 178 E.C.S.S......................................................................................................... 180 WORK EQUIPMENT CONTROL VALVE.................................................................................... 182 2-SPOOL VALVE............................................................................................... 182 3-SPOOL VALVE............................................................................................... 185 RELIEF VALVE................................................................................................ 188 FUNCTION................................................................................................ 188 OPERATION............................................................................................... 188 SAFETY-SUCTION VALVE........................................................................................ 189 FUNCTION................................................................................................ 189 OPERATION............................................................................................... 189 SUCTION VALVE............................................................................................... 190 FUNCTION................................................................................................ 190 OPERATION............................................................................................... 190 CUT-OFF VALVE............................................................................................... 191 FUNCTION................................................................................................ 191 WORK EQUIPMENT CONTROL VALVE OPERATION...................................................................... 193 NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS...................................................... 193 RAISED POSITION FOR THE LIFT ARM SPOOL.................................................................. 194 LOWER POSITION OF THE LIFT ARM SPOOL.................................................................... 195 FLOAT POSITION OF THE LIFT ARM SPOOL.................................................................... 196 DUMP POSITION FOR THE BUCKET SPOOL...................................................................... 197 TILT POSITION FOR THE BUCKET SPOOL...................................................................... 198 WORK EQUIPMENT PPC VALVE........................................................................................ 199 OPERATION................................................................................................... 201 ATTACHMENT PPC VALVE............................................................................................ 205 OPERATION................................................................................................... 207 COOLING FAN MOTOR............................................................................................... 209 MODEL: LMF28................................................................................................ 209 HYDRAULIC MOTOR......................................................................................... 211 SUCTION VALVE........................................................................................... 212 OPERATION OF REVOLUTION DIRECTION CHANGEOVER VALVE...................................................... 213 COOLING FAN MOTOR DRIVE PUMP.................................................................................... 214 MODEL: LPV.................................................................................................. 214 SERVO VALVE............................................................................................. 219 SAFETY VALVE............................................................................................ 221 WORK EQUIPMENT LINKAGE.......................................................................................... 222 BUCKET.......................................................................................................... 224 BUCKET POSITIONER, LIFT ARM KICK-OUT............................................................................ 225 BUCKET POSITIONER........................................................................................... 226 LIFT ARM KICK-OUT........................................................................................... 226 PROXIMITY SWITCH OPERATION...................................................................................... 227 WHEN LIFT ARM IS RAISED..................................................................................... 227 WHEN BUCKET IS TILTED....................................................................................... 229 WORK EQUIPMENT CYLINDER......................................................................................... 231 LIFT ARM CYLINDER........................................................................................... 231 BUCKET CYLINDER............................................................................................. 231 CAB............................................................................................................. 233 AIR CONDITIONER................................................................................................. 234 AIR CONDITIONER PIPING...................................................................................... 234 MACHINE MONITORING SYSTEM....................................................................................... 235 OUTLINE..................................................................................................... 235 INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR.......................................................... 237 STARTING AND LIGHTING FUNCTIONS......................................................................... 237 LOAD METER.............................................................................................. 237 SENSING FUNCTIONS....................................................................................... 238 POWER SUPPLY AND NETWORK................................................................................ 239 AUTOMATIC PREHEATING FUNCTION........................................................................... 240 MACHINE MONITOR................................................................................................. 242 STANDARD SPECIFICATIONS..................................................................................... 242 LOAD METER SPECIFICATION.................................................................................... 243 TABLE OF MONITOR INDICATION ITEMS........................................................................... 244 SETTING THE MACHINE MONITOR................................................................................. 251 SERVICE MODE FUNCTIONS.................................................................................. 254 ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM................................................... 257 ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM.................................................... 259 ITEMS RELATED TO MAINTENANCE MONITOR.................................................................... 260 REAL-TIME MONITORING FUNCTION........................................................................... 263 REAL-TIME MONITORING ITEMS.............................................................................. 265 MACHINE SETTING......................................................................................... 276 SETTING NECESSARY FOR OPTION MOUNTING................................................................... 279 OPTIONAL DEVICE SETTING FOR MACHINE MONITOR............................................................. 280 TRANSMISSION CONTROL SYSTEM..................................................................................... 292 SYSTEM DIAGRAM.............................................................................................. 292 CONTROL FUNCTION........................................................................................ 293 ELECTRIC CIRCUIT DIAGRAM (STANDARD)..................................................................... 310 TRANSMISSION CONTROLLER......................................................................................... 314 WORK EQUIPMENT CONTROL SYSTEM................................................................................... 316 ELECTRIC CIRCUIT DIAGRAM.................................................................................... 319 JOYSTICK OPTION ONLY.................................................................................... 319 WORK EQUIPMENT CONTROLLER....................................................................................... 321 JOYSTICK OPTION............................................................................................. 321 ELECTRIC TRANSMISSION CONTROL................................................................................... 324 FUNCTION.................................................................................................... 325 COMBINATION SWITCH.......................................................................................... 326 FUNCTION................................................................................................ 326 OPERATION............................................................................................... 327 KICK DOWN, HOLD SWITCH.......................................................................................... 328 FUNCTION.................................................................................................... 328 ENGINE START CIRCUIT............................................................................................ 329 FUNCTION.................................................................................................... 329 OPERATION................................................................................................... 330 ENGINE STOP CIRCUIT............................................................................................. 331 OPERATION................................................................................................... 331 PREHEATING CIRCUIT.............................................................................................. 332 AUTOMATIC PREHEATING SYSTEM................................................................................. 332 OUTLINE................................................................................................. 332 OPERATION............................................................................................... 332 ENGINE POWER MODE SELECTOR CIRCUIT.............................................................................. 333 FUNCTION.................................................................................................... 333 OPERATION................................................................................................... 333 PARKING BRAKE CIRCUIT........................................................................................... 334 OPERATION................................................................................................... 334 SENSORS......................................................................................................... 338 ENGINE SPEED SENSOR......................................................................................... 338 FUNCTION................................................................................................ 338 ENGINE OIL PRESSURE SENSOR.................................................................................. 339 FUNCTION................................................................................................ 339 ENGINE OIL LEVEL SENSOR..................................................................................... 339 FUNCTION................................................................................................ 339 TEMPERATURE SENSOR.......................................................................................... 340 COOLANT (FOR MONITOR), TORQUE CONVERTER OIL, HYDRAULIC OIL, TRANSMISSION OIL, BRAKE OIL................. 340 COOLANT TEMPERATURE SENSOR - PREHEATING................................................................. 340 FUNCTION................................................................................................ 340 TRANSMISSION CUT-OFF PRESSURE SENSOR........................................................................ 341 FUNCTION................................................................................................ 341 COOLANT LEVEL SENSOR........................................................................................ 342 FUNCTION................................................................................................ 342 FUEL LEVEL SENSOR........................................................................................... 343 FUNCTION................................................................................................ 343 BOOM ANGLE SENSOR FOR LOAD METER............................................................................ 344 FUNCTION................................................................................................ 344 AIR CLEANER CLOGGING SENSOR................................................................................. 345 FUNCTION................................................................................................ 345 LOAD METER PRESSURE SENSOR.................................................................................. 346 FUNCTION................................................................................................ 346 BATTERY FLUID LEVEL SENSOR.................................................................................. 347 FUNCTION................................................................................................ 347 RELAY....................................................................................................... 348 20 TESTING, ADJUSTING AND TROUBLESHOOTING........................................................................... 349 STANDARD VALUE TABLE FOR ENGINE................................................................................. 351 STANDARD VALUE TABLE FOR CHASSIS................................................................................ 352 SPECIAL TOOLS................................................................................................... 359 ENGINE COMPONENTS............................................................................................... 361 MEASURING EXHAUST SMOKE..................................................................................... 361 MEASURING EXHAUST TEMPERATURE............................................................................... 361 ADJUSTING VALVE CLEARANCE................................................................................... 361 MEASURING COMPRESSION PRESSURE.............................................................................. 361 MEASURING CRANCASE PRESSURE................................................................................. 361 MEASURING ENGINE OIL PRESSURE............................................................................... 361 MEASURING BOOST PRESSURE.................................................................................... 361 MEASURING FUEL PRESSURE..................................................................................... 361 ADJUSTING ENGINE SPEED SENSOR............................................................................... 361 BLEEDING AIR FROM FUEL SYSTEM............................................................................... 361 MEASURING ENGINE SPEED...................................................................................... 362 ADJUSTING ACCELERATOR PEDAL..................................................................................... 364 ADJUSTING THE POWER MODE.................................................................................... 364 ADJUSTING THE NORMAL MODE................................................................................... 365 ADJUSTING TRANSMISSION SPEED SENSOR............................................................................. 366 POWER TRAIN OIL PRESSURE........................................................................................ 367 FLUSHING........................................................................................................ 372 TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT........................................................ 372 TRANSMISSION VALVE FAILS........................................................................................ 373 MOVING MACHINE.............................................................................................. 373 STEERING CONTROL................................................................................................ 375 STEERING OIL PRESSURE........................................................................................... 376 TESTING HYDRAULIC FAN........................................................................................... 378 BRAKE SYSTEM.................................................................................................... 379 MEASURING BRAKE OIL PRESSURE................................................................................ 379 TESTING WEAR OF WHEEL BRAKE DISC............................................................................ 381 BLEEDING AIR FROM BRAKE CIRCUIT............................................................................. 382 TESTING WEAR OF PARKING BRAKE DISC.......................................................................... 383 MANUAL RELEASE METHOD FOR PARKING BRAKE..................................................................... 384 ACCUMULATOR CHARGE PRESSURE..................................................................................... 385 PPC OIL PRESSURE................................................................................................ 387 WORK EQUIPMENT HYDRAULIC PRESSURE............................................................................... 390 BUCKET POSITIONER............................................................................................... 392 LIFT ARM KICK-OUT............................................................................................... 393 PROXIMITY SWITCH ACTUATION...................................................................................... 394 ADJUSTING MACHINE MONITOR....................................................................................... 395 LOAD METER...................................................................................................... 398 BLEEDING AIR.................................................................................................... 402 RELEASING REMAINING PRESSURE.................................................................................... 403 IN HYDRAULIC CIRCUIT........................................................................................ 403 E.C.S.S. DAMPER CIRCUIT..................................................................................... 404 PM-CLINIC INSPECTION TABLE...................................................................................... 405 GENERAL TROUBLESHOOTING......................................................................................... 409 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................... 410 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................... 412 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................................... 413 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT.......................................................... 413 HANDLING ELECTRONIC CONTROL UNIT........................................................................ 418 WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS................................................................ 419 WHEN HANDLING HYDRAULIC EQUIPMENT....................................................................... 420 CHECKS BEFORE TROUBLESHOOTING............................................................................... 422 EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM............................................................. 422 SPECIAL FUNCTIONS OF MACHINE MONITOR........................................................................ 424 FLOW OF MODES AND FUNCTIONS............................................................................. 425 FAILURE CODE TABLE...................................................................................... 433 MONITORING CODE TABLE................................................................................... 446 USING TROUBLESHOOTING CHARTS................................................................................ 458 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................. 462 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................. 482 CONNECTOR TYPES AND LOCATIONS............................................................................... 484 CONNECTOR LAYOUT DRAWING.................................................................................... 492 TRANSMISSION CONTROL SYSTEM DIAGRAM......................................................................... 498 ERROR CODE [1500L1]......................................................................................... 501 DOUBLE ENGAGEMENT DETECTED.............................................................................. 501 ERROR CODE [15SAL1]......................................................................................... 502 F_ECMV FILL SWITCH SYSTEM SHORTED....................................................................... 502 ERROR CODE [15SALH]......................................................................................... 503 F_ECMV FILL SWITCH SYSTEM OPEN.......................................................................... 503 ERROR CODE [15SBL1]......................................................................................... 504 R_ECMV FILL SWITCH SYSTEM SHORTED....................................................................... 504 ERROR CODE [15SBLH]......................................................................................... 505 R_ECMV FILL SWITCH SYSTEM OPEN.......................................................................... 505 ERROR CODE [15SEL1]......................................................................................... 506 1ST_ECMV FILL SWITCH SYSTEM SHORTED..................................................................... 506 ERROR CODE [15SELH]......................................................................................... 508 1ST_ECMV FILL SWITCH SYSTEM open........................................................................ 508 ERROR CODE [15SFL1]......................................................................................... 510 2ND_ECMV FILL SWITCH SYSTEM SHORTED..................................................................... 510 ERROR CODE [15SFLH]......................................................................................... 512 2ND_ECMV FILL SWITCH SYSTEM OPEN........................................................................ 512 ERROR CODE [15SGL1]......................................................................................... 514 3RD_ECMV FILL SWITCH SYSTEM SHORTED..................................................................... 514 ERROR CODE [15SGLH]......................................................................................... 516 3RD_ECMV FILL SWITCH SYSTEM OPEN........................................................................ 516 ERROR CODE [15SHL1]......................................................................................... 518 4TH_ECMV FILL SWITCH SYSTEM SHORTED..................................................................... 518 ERROR CODE [15SHLH]......................................................................................... 520 4TH_ECMV FILL SWITCH SYSTEM OPEN........................................................................ 520 ERROR CODE [15SJL1]......................................................................................... 522 LOCKUP_ECMV FILL SWITCH SYSTEM SHORTED.................................................................. 522 ERROR CODE [15SJLH]......................................................................................... 523 LOCKUP_ECMV FILL SWITCH SYSTEM OPEN..................................................................... 523 ERROR CODE [989F00]......................................................................................... 524 TRANSMISSION PROTECTION CAUTION......................................................................... 524 ERROR CODE [B@C7NS]......................................................................................... 526 REAR BRAKE COOLING OIL OVERHEAT FAULT................................................................... 526 ERROR CODE [D150KA]......................................................................................... 528 EMERGENCY STEERING RELAY SYSTEM OPEN.................................................................... 528 ERROR CODE [D150KB]......................................................................................... 529 EMERGENCY STEERING RELAY SYSTEM SHORTED................................................................. 529 ERROR CODE [D160KA]......................................................................................... 530 BACKUP LAMP RELAY SYSTEM OPEN........................................................................... 530 ERROR CODE [D160KB]......................................................................................... 531 BACKUP LAMP RELAY SYSTEM SHORTED........................................................................ 531 ERROR CODE [D191KA]......................................................................................... 532 NEUTRAL SAFETY RELAY SYSTEM OPEN........................................................................ 532 ERROR CODE [D191KB]......................................................................................... 534 NEUTRAL SAFETY RELAY SYSTEM SHORTED..................................................................... 534 ERROR CODE [D192KA]......................................................................................... 536 TRAVEL DAMPER RELAY SYSTEM OPEN......................................................................... 536 ERROR CODE [D192KB]......................................................................................... 537 TRAVEL DAMPER RELAY SYSTEM SHORTED...................................................................... 537 ERROR CODE [D198KB]......................................................................................... 538 LOW TEMPERATURE BYPASS RELAY SYSTEM SHORTED............................................................. 538 ERROR CODE [D198KY]......................................................................................... 540 LOW TEMPERATURE BYPASS RELAY SYSTEM OPEN................................................................ 540 ERROR CODE [DAQ0KK]......................................................................................... 542 CONTROLLER POWER SUPPLY TO MONITOR LOW.................................................................. 542 ERROR CODE [DAQ2KK]......................................................................................... 543 DEFECTIVE SOLENOID POWER SUPPLY......................................................................... 543 ERROR CODE [DAQ9KQ]......................................................................................... 544 MODEL SELECTION SIGNAL MISMATCH......................................................................... 544 ERROR CODE [DDK3KA]......................................................................................... 546 NO JOYSTICK FORWARD/REVERSE SIGNAL...................................................................... 546 ERROR CODE [DDK4KB]......................................................................................... 548 MULTIPLE JOYSTICK FORWARD OR/REVERSE SIGNALS............................................................ 548 ERROR CODE [DDK4KA]......................................................................................... 550 NO INPUT FROM JOYSTICK SWITCH........................................................................... 550 ERROR CODE [DDK4KB]......................................................................................... 552 NO INPUT FROM JOYSTICK SWITCH........................................................................... 552 ERROR CODE [DDK5LD]......................................................................................... 554 SHORT CIRCUIT IN POWER SOURCE FOR JOYSTICK SHIFT UP/SHIFT DOWN SWITCH................................... 554 ERROR CODE [DDK6KA]......................................................................................... 556 FORWARD-REVERSE SIGNAL FAULT............................................................................ 556 ERROR CODE [DDK6KB]......................................................................................... 558 MULTIPLE FORWARD-REVERSE SIGNAL INPUTS.................................................................. 558 ERROR CODE [DDS5KA]......................................................................................... 560 STEERING PRESSURE SWITCH OPEN........................................................................... 560 ERROR CODE [DDS5KB]......................................................................................... 562 STEERING PRESSURE SWITCH SHORTED........................................................................ 562 ERROR CODE [DDT0L4]......................................................................................... 564 MANUAL/AUTO-SHIFT SELECTOR SELECTION FAILURE............................................................ 564 ERROR CODE [DDT4LD]......................................................................................... 566 GROUND FAULT IN TRANSMISSION CUT-OFF SWITCH............................................................. 566 ERROR CODE [DDW9LD]......................................................................................... 568 SHORT IN KICKDOWN SWITCH SYSTEM......................................................................... 568 ERROR CODE [DDWLLD]......................................................................................... 570 GROUND FAULT IN HOLD SWITCH SYSTEM...................................................................... 570 ERROR CODE [DF10KA]......................................................................................... 572 NO INPUT SIGNAL IN GEAR SHIFT LEVER..................................................................... 572 ERROR CODE [DF10KB]......................................................................................... 574 MULTIPLE GEAR SHIFT LEVER SIGNALS....................................................................... 574 ERROR CODE [DGF1KX]......................................................................................... 576 TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE...................................................... 576 ERROR CODE [DGR2KA]......................................................................................... 578 REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM OPEN........................................................... 578 ERROR CODE [DGR2KB]......................................................................................... 580 GROUND FAULT IN REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM................................................ 580 ERROR CODE [DHT1KX]......................................................................................... 581 TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL OPEN........................................... 581 ERROR CODE [DLE2KA]......................................................................................... 582 ENGINE SPEED SENSOR OPEN................................................................................ 582 ERROR CODE [DLE2LC]......................................................................................... 583 ENGINE SPEED SENSOR SHORTED............................................................................. 583 ERROR CODE [DLT3KA]......................................................................................... 584 SPEED SENSOR SYSTEM OPEN................................................................................ 584 ERROR CODE [DT20KB]......................................................................................... 585 GROUND FAULT IN INDICATOR LAMP SYSTEM (TRANSMISSION CUT-OFF SWITCH)..................................... 585 ERROR CODE [DW7BKA]......................................................................................... 586 FAN PUMP REVERSE SOLENOID SYSTEM OPEN................................................................... 586 ERROR CODE [DW7BKB]......................................................................................... 587 FAN REVERSE SOLENOID SYSTEM SHORTED..................................................................... 587 ERROR CODE [DW7CKA]......................................................................................... 588 SWITCH PUMP CUT-OFF RELAY OPEN.......................................................................... 588 ERROR CODE [DW7CKB]......................................................................................... 589 SWITCH PUMP CUT-OFF RELAY GROUND FAULT.................................................................. 589 ERROR CODE [DX16KA]......................................................................................... 590 FAN PUMP EPC SOLENOID SYSTEM OPEN....................................................................... 590 ERROR CODE [DX16KB]......................................................................................... 591 FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT............................................................... 591 ERROR CODE [DXH1KA]......................................................................................... 592 LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM OPEN................................................................ 592 ERROR CODE [DXH1KB]......................................................................................... 593 LOCK-UP CLUTCH ECMV SOLENOID SYSTEM SHORTED............................................................. 593 ERROR CODE [DXH4KA]......................................................................................... 594 1ST_ECMV SOLENOID SYSTEM OPEN........................................................................... 594 ERROR CODE [DXH4KB]......................................................................................... 595 1ST_ECMV SOLENOID SYSTEM SHORTED........................................................................ 595 ERROR CODE [DXH5KA]......................................................................................... 596 2ND_ECMV SOLENOID SYSTEM OPEN........................................................................... 596 ERROR CODE [DXH5KB]......................................................................................... 597 2ND_ECMV SOLENOID SYSTEM SHORTED........................................................................ 597 ERROR CODE [DXH6KA]......................................................................................... 598 3RD_ECMV SOLENOID SYSTEM OPEN........................................................................... 598 ERROR CODE [DXH6KB]......................................................................................... 599 3RD_ECMV SOLENOID SYSTEM SHORTED........................................................................ 599 ERROR CODE [DXH7KA]......................................................................................... 600 R_ECMV SOLENOID SYSTEM OPEN............................................................................. 600 ERROR CODE [DXH7KB]......................................................................................... 601 R_ECMV SOLENOID SYSTEM GROUND FAULT..................................................................... 601 ERROR CODE [DXH8KA]......................................................................................... 602 F_ECMV SOLENOID SYSTEM OPEN............................................................................. 602 ERROR CODE [DXH8KB]......................................................................................... 603 F_ECMV SOLENOID SYSTEM GROUND FAULT..................................................................... 603 ERROR CODE [DXHHKA]......................................................................................... 604 4TH_ECMV SOLENOID SYSTEM OPEN........................................................................... 604 ERROR CODE [DXHHKB]......................................................................................... 605 4TH_ECMV SOLENOID SYSTEM SHORTED........................................................................ 605 ERROR CODE [DY30MA]......................................................................................... 606 MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE............................................................ 606 ERROR CODE [DY30MC]......................................................................................... 608 MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE............................................................ 608 ACTION CODE [TM-1].......................................................................................... 610 OPEN OR SHORT IN KICKDOWN SWITCH SYSTEM................................................................. 610 ACTION CODE [TM-2].......................................................................................... 612 HOLD SWITCH SYSTEM OPEN OR SHORT........................................................................ 612 ACTION CODE [TM-3].......................................................................................... 614 TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE.......................................................... 614 ACTION CODE [TM-4].......................................................................................... 616 NEUTRAL SIGNAL SYSTEM FAILURE........................................................................... 616 ACTION CODE [TM-5].......................................................................................... 618 EMERGENCY STEERING SWITCH SIGNAL SYSTEM FAILURE......................................................... 618 ACTION CODE [TM-6].......................................................................................... 620 TRANSMISSION CUT-OFF SWITCH SYSTEM OPEN OR SHORTED...................................................... 620 ACTION CODE [TM-7].......................................................................................... 621 TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM OPEN OR SHORTED.............................................. 621 ACTION CODE [TM-8].......................................................................................... 622 TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORTED................................................. 622 ACTION CODE [TM-9].......................................................................................... 623 JOYSTICK SHIFT UP/SHIFT DOWN SWITCH SYSTEM FAILURE...................................................... 623 ACTION CODE [TM-10A]........................................................................................ 624 JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE....................................................... 624 ACTION CODE [TM-10B]........................................................................................ 626 IGNITION SWITCH "C" (IGN C) SIGNAL SYSTEM FAILURE....................................................... 626 ACTION CODE [TM-11]......................................................................................... 628 FNR SWITCH SYSTEM FAILURE............................................................................... 628 ACTION CODE [TM-12]......................................................................................... 629 ENGINE POWER MODE SWITCH OPEN OR SHORTED................................................................ 629 ACTION CODE [TM-13]......................................................................................... 630 OPEN OR SHORT IN TRAVEL DAMPER ON/OFF SWITCH............................................................ 630 ACTION CODE [TM-14]......................................................................................... 631 OPEN OR SHORT IN HYDRAULIC FAN REVERSE SIGNAL SYSTEM.................................................... 631 ACTION CODE [TM-15]......................................................................................... 632 SHORT IN MOTOR DRIVEN EMERGENCY STEERING RELAY SYSTEM................................................... 632 ACTION CODE [TM-16]......................................................................................... 633 SHORT IN TRAVEL DAMPER RELAY SYSTEM..................................................................... 633 ACTION CODE [TM-17]......................................................................................... 634 SWITCH PUMP CUT-OFF RELAY SYSTEM SHORTED................................................................ 634 ACTION CODE [TM-18]......................................................................................... 635 BACK LAMP RELAY SYSTEM SHORTED.......................................................................... 635 ACTION CODE [TM-19]......................................................................................... 636 NEUTRAL SYSTEM SHORTED.................................................................................. 636 ACTION CODE [TM-20]......................................................................................... 638 F_ECMV SOLENOID SYSTEM SHORTED.......................................................................... 638 ACTION CODE [TM-21]......................................................................................... 639 R_ECMV SOLENOID SYSTEM SHORTED.......................................................................... 639 ACTION CODE [TM-22]......................................................................................... 640 1ST_ECMV SOLENOID SYSTEM SHORTED........................................................................ 640 ACTION CODE [TM-23]......................................................................................... 641 2ND_ECMV SOLENOID SYSTEM SHORTED........................................................................ 641 ACTION CODE [TM-24]......................................................................................... 642 3RD_ECMV SOLENOID SYSTEM SHORTED........................................................................ 642 ACTION CODE [TM-25]......................................................................................... 643 4TH_ECMV SOLENOID SYSTEM SHORTED........................................................................ 643 ACTION CODE [TM-26]......................................................................................... 644 LOCK-UP ECMV SOLENOID SYSTEM SHORTED.................................................................... 644 ACTION CODE [TM-27]......................................................................................... 645 FAN PUMP EPC SOLENOID SYSTEM SHORTED.................................................................... 645 ACTION CODE [TM-28]......................................................................................... 646 FAN REVERSE SOLENOID SYSTEM SHORTED..................................................................... 646 ACTION CODE [TM-29]......................................................................................... 647 SPEED SENSOR SYSTEM FAILURE............................................................................. 647 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................. 654 CONNECTOR TYPES AND LOCATIONS............................................................................... 656 CONNECTOR LAYOUT DRAWING.................................................................................... 664 WORK EQUIPMENT SYSTEM DIAGRAM............................................................................... 670 ERROR CODE [D193KA]......................................................................................... 674 DEFECTIVE JOYSTICK STEERING RELAY SYSTEM................................................................ 674 ERROR CODE [D193KB]......................................................................................... 676 JOYSTICK SOLENOID RELAY OUTPUT SYSTEM SHORTED........................................................... 676 ERROR CODE [DB90KK]......................................................................................... 678 LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY FAULT................................................... 678 ERROR CODE [DB92KK]......................................................................................... 680 DEFECTIVE SOLENOID POWER SUPPLY......................................................................... 680 ERROR CODE [DB95KX]......................................................................................... 682 OPEN IN 5 V POWER SUPPLY................................................................................ 682 ERROR CODE [DD1ALD]......................................................................................... 684 DEFECTIVE REMOTE UP SWITCH.............................................................................. 684 ERROR CODE [DD1BLD]......................................................................................... 686 DEFECTIVE REMOTE DOWN SWITCH............................................................................ 686 ERROR CODE [DFAOKM]......................................................................................... 688 DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT................................................... 688 ERROR CODE [DK59KA]......................................................................................... 690 DEFECTIVE EPC POTENTIOMETER............................................................................. 690 ERROR CODE [DK59KY]......................................................................................... 692 DEFECTIVE EPC POTENTIOMETER............................................................................. 692 ERROR CODE [DK59L8]......................................................................................... 694 DEFECTIVE EPC POTENTIOMETER............................................................................. 694 ERROR CODE [DK5AKA]......................................................................................... 696 DEFECTIVE EPC POTENTIOMETER............................................................................. 696 ERROR CODE [DK5AKY]......................................................................................... 698 DEFECTIVE EPC POTENTIOMETER............................................................................. 698 ERROR CODE [DK5BKA]......................................................................................... 700 DEFECTIVE EPC POTENTIOMETER............................................................................. 700 ERROR CODE [DK5BKY]......................................................................................... 702 DEFECTIVE EPC POTENTIOMETER............................................................................. 702 ERROR CODE [DK5BL8]......................................................................................... 704 DEFECTIVE EPC POTENTIOMETER............................................................................. 704 ERROR CODE [DK5CKA]......................................................................................... 706 DEFECTIVE EPC POTENTIOMETER............................................................................. 706 ERROR CODE [DK5CKY]......................................................................................... 708 DEFECTIVE EPC POTENTIOMETER............................................................................. 708 ERROR CODE [DK5DKA]......................................................................................... 710 DEFECTIVE 3RD VALVE POTENTIOMETER LEVER................................................................. 710 ERROR CODE [DK5DL8]......................................................................................... 712 DEFECTIVE 3RD EPC POTENTIOMETER......................................................................... 712 ERROR CODE [DK5EKA]......................................................................................... 714 DEFECTIVE 3RD VALVE POTENTIOMETER LEVER................................................................. 714 ERROR CODE [DK5EKY]......................................................................................... 716 DEFECTIVE 3RD VALVE POTENTIOMETER LEVER................................................................. 716 ERROR CODE [DK5FKA]......................................................................................... 718 DEFECTIVE JOYSTICK STEERING EPC SYSTEM (MAIN CIRCUIT OPEN OR SHORTED)................................... 718 ERROR CODE [DK5FKY]......................................................................................... 720 DEFECTIVE JOYSTICK STEERING EPC POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)............................. 720 ERROR CODE [DK5FKM]......................................................................................... 721 JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION...................................................... 721 ERROR CODE [DK5FL8]......................................................................................... 722 DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER INPUT SIGNAL........................................ 722 ERROR CODE [DK5GKA]......................................................................................... 724 DEFECTIVE JOYSTICK STEERING EPC POTENTIOMETER SYSTEM (OPEN OR SHORT IN SUB CIRCUIT)..................... 724 ERROR CODE [DK5GKY]......................................................................................... 726 DEFECTIVE JOYSTICK STEERING EPC POTENTIOMETER SYSTEM (SUB CIRCUIT SHORT)................................ 726 ERROR CODE [DKAOKA]......................................................................................... 728 DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (OPEN OR SHORT).................................................. 728 ERROR CODE [DKAOKY]......................................................................................... 730 DEFECTIVE LIFT ARM ANGLE SENSOR (SYSTEM SHORTED)........................................................ 730 ERROR CODE [DLE2LC]......................................................................................... 732 DEFECTIVE ENGINE SPEED SENSOR SYSTEM.................................................................... 732 ERROR CODE [DLT3LC]......................................................................................... 733 DEFECTIVE TRANSMISSION OUTPUT AXLE SPEED SENSOR SYSTEM (OPEN)........................................... 733 ERROR CODE [DUM1KB]......................................................................................... 734 REMOTE POSITIONER GROUND FAULT.......................................................................... 734 ERROR CODE [DUM2KB]......................................................................................... 735 REMOTE POSITIONER GROUND FAULT.......................................................................... 735 ERROR CODE [DW4PKA]......................................................................................... 736 RAISE EPC SOLENOID FAULT................................................................................ 736 ERROR CODE [DW4PKB]......................................................................................... 737 RAISE EPC SOLENOID FAULT................................................................................ 737 ERROR CODE [DW4QKA]......................................................................................... 738 LOWER EPC SOLENOID FAULT................................................................................ 738 ERROR CODE [DW4QKB]......................................................................................... 739 LOWER EPC SOLENOID FAULT................................................................................ 739 ERROR CODE [DW4RKA]......................................................................................... 740 TILT EPC SOLENOID FAULT................................................................................. 740 ERROR CODE [DW4RKB]......................................................................................... 741 TILT EPC SOLENOID FAULT................................................................................. 741 ERROR CODE [DW4SKA]......................................................................................... 742 DUMP EPC SOLENOID FAULT................................................................................. 742 ERROR CODE [DW4SKB]......................................................................................... 743 DUMP EPC SOLENOID FAULT................................................................................. 743 ERROR CODE [DWM1KA]......................................................................................... 744 LOCK EPC SOLENOID FAULT................................................................................. 744 ERROR CODE [DWM1KB]......................................................................................... 745 LOCK EPC SOLENOID FAULT................................................................................. 745 ERROR CODE [DWN6KA]......................................................................................... 746 DEFECTIVE RAISE DETENT SYSTEM........................................................................... 746 ERROR CODE [DWN6KB]......................................................................................... 748 DEFECTIVE RAISE DETENT SYSTEM........................................................................... 748 ERROR CODE [DWN7KA]......................................................................................... 750 DEFECTIVE FLOAT DETENT SYSTEM........................................................................... 750 ERROR CODE [DWN7KB]......................................................................................... 752 DEFECTIVE FLOAT DETENT SYSTEM........................................................................... 752 ERROR CODE [DWN8KA]......................................................................................... 754 DEFECTIVE TILT DETENT SYSTEM............................................................................ 754 ERROR CODE [DWN8KB]......................................................................................... 756 DEFECTIVE TILT DETENT SYSTEM............................................................................ 756 ERROR CODE [DXHJKA]......................................................................................... 758 3RD VALVE EPC SOLENOID FAULT............................................................................ 758 ERROR CODE [DXHJKB]......................................................................................... 759 3RD VALVE EPC SOLENOID FAULT............................................................................ 759 ERROR CODE [DXHKKA]......................................................................................... 760 3RD VALVE EPC SOLENOID FAULT............................................................................ 760 ERROR CODE [DXHKKB]......................................................................................... 761 3RD VALVE EPC SOLENOID FAULT............................................................................ 761 ERROR CODE: [DXHLKA]........................................................................................ 762 OPEN IN JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM................................................ 762 ERROR CODE: [DXHLKB]........................................................................................ 764 JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT........................................... 764 ERROR CODE: [DXHMKA]........................................................................................ 766 JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM OPEN.................................................... 766 ERROR CODE: [DXHMKB]........................................................................................ 768 JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT............................................ 768 [WRK-1]..................................................................................................... 770 LIFT ARM LOCK SWITCH FAILURE............................................................................ 770 [WRK-2]..................................................................................................... 772 DEFECTIVE REMOTE POSITIONER RAISE SETTING............................................................... 772 [WRK-3]..................................................................................................... 774 DEFECTIVE REMOTE POSITIONER LOWER SETTING............................................................... 774 [WRK-4]..................................................................................................... 776 DEFECTIVE REMOTE POSITIONER RAISE SETTING............................................................... 776 [WRK-5]..................................................................................................... 778 DEFECTIVE REMOTE POSITIONER LOWER SETTING............................................................... 778 [WRK-6]..................................................................................................... 780 DEFECTIVE BUCKET PROXIMITY SWITCH....................................................................... 780 [WRK-7]..................................................................................................... 782 DEFECTIVE BUCKET FULL STROKE SWITCH..................................................................... 782 [WRK-8]..................................................................................................... 784 DEFECTIVE SEMI-AUTO DIGGING SYSTEM...................................................................... 784 [WRK-9]..................................................................................................... 786 DEFECTIVE SEMI-AUTO DIGGING SYSTEM...................................................................... 786 [WRK-10].................................................................................................... 788 DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM................................................................. 788 [WRK-11].................................................................................................... 790 DEFECTIVE JOYSTICK STEERING HI/LO SYSTEM................................................................ 790 [WRK-12].................................................................................................... 792 DEFECTIVE JOYSTICK SOLENOID RELAY SYSTEM................................................................ 792 [WRK-13].................................................................................................... 794 DEFECTIVE RAISE DETENT SYSTEM........................................................................... 794 [WRK-14].................................................................................................... 796 DEFECTIVE FLOAT DETENT SYSTEM........................................................................... 796 [WRK-15].................................................................................................... 798 DEFECTIVE TILT DETENT SYSTEM............................................................................ 798 [WRK-16].................................................................................................... 800 LOCK EPC SOLENOID FAULT................................................................................. 800 [WRK-17].................................................................................................... 801 RAISE EPC SOLENOID FAULT................................................................................ 801 [WRK-18].................................................................................................... 802 LOWER EPC SOLENOID FAULT................................................................................ 802 [WRK-19].................................................................................................... 803 TILT EPC SOLENOID FAULT................................................................................. 803 [WRK-20].................................................................................................... 804 DUMP EPC SOLENOID FAULT................................................................................. 804 [WRK-21].................................................................................................... 805 3RD VALVE EPC SOLENOID FAULT............................................................................ 805 [WRK-22].................................................................................................... 806 3RD VALVE EPC SOLENOID FAULT............................................................................ 806 [WRK-23].................................................................................................... 807 SHORT IN JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM.................................................... 807 [WRK-24].................................................................................................... 808 SHORT IN JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM..................................................... 808 [WRK-25].................................................................................................... 809 DEFECTIVE KICK-OUT FUNCTION BUCKET FLOAT................................................................ 809 [WRK-26].................................................................................................... 812 DEFECTIVE KICK-OUT FUNCTION LIFT ARM.................................................................... 812 [WRK-27].................................................................................................... 815 DEFECTIVE BUCKET LEVER FUNCTION......................................................................... 815 [WRK-28].................................................................................................... 818 DEFECTIVE FLOAT FUNCTION................................................................................ 818 INFORMATION CONTAINED IN TESTING PROCEDURES................................................................. 824 CONNECTOR TYPES AND LOCATIONS........................................................................... 826 CONNECTOR LAYOUT DRAWING.................................................................................... 834 MONITOR SYSTEM DIAGRAM...................................................................................... 840 ERROR CODE [2F00MA]......................................................................................... 844 PARKING BRAKE FAILURE................................................................................... 844 ERROR CODE [2G42ZG]......................................................................................... 846 ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW............................................................ 846 ERROR CODE [2G43ZG]......................................................................................... 848 ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW....................................................... 848 ERROR CODE [AA1ANX]......................................................................................... 850 AIR CLEANER 1 CLOGGED................................................................................... 850 ERROR CODE [AB00L6]......................................................................................... 852 DEFECTIVE BATTERY CHARGING CIRCUIT...................................................................... 852 ERROR CODE [AB00MA]......................................................................................... 854 THE BATTERY CHARGING CIRCUIT IS OUT OF ORDER............................................................ 854 ERROR CODE [B@BAZG]......................................................................................... 856 ENGINE OIL PRESSURE LOW................................................................................. 856 ERROR CODE [B@BAZK]......................................................................................... 857 ENGINE OIL LEVEL LOW.................................................................................... 857 ERROR CODE [B@BCNS]......................................................................................... 858 ENGINE COOLANT TEMPERATURE OVERHEATING.................................................................. 858 ERROR CODE [B@BCZK]......................................................................................... 859 ALARM INDICATING LOW COOLANT LEVEL...................................................................... 859 ERROR CODE [B@HANS]......................................................................................... 860 HYDRAULIC OIL TEMPERATURE OVERHEATING................................................................... 860 ERROR CODE [B@CENS]......................................................................................... 861 TORQUE CONVERTER OIL TEMPERATURE OVERHEATING............................................................ 861 ERROR CODE [D182KZ]......................................................................................... 862 THE PREHEATER RELAY COIL IS OPEN OR SHORTED............................................................. 862 ERROR CODE [D5ZHL6]......................................................................................... 864 START SWITCH C (IGN "C") INPUT FAILURE.................................................................. 864 ERROR CODE [DA80L4]......................................................................................... 866 AUTO-GREASE INPUT ABNORMAL.............................................................................. 866 ERROR CODE [DAF3KK]......................................................................................... 868 WHEN THE SW POWER SUPPLY (FOR OPERATION) IS ON, THE NSW POWER SUPPLY (FOR MEMORY) IS OFF................ 868 ERROR CODE [DAF5KP]......................................................................................... 870 5-V POWER SUPPLY OUTPUT FAILURE......................................................................... 870 ERROR CODE [DAF6KP]......................................................................................... 872 24-V POWER SUPPLY OUTPUT FAILURE........................................................................ 872 ERROR CODE [DAFBKM]......................................................................................... 874 INCORRECT INFORMATION ON MODEL SELECTION................................................................ 874 ERROR CODE [DAFSKQ]......................................................................................... 875 INCORRECT INFORMATION ON METER INDICATION SELECTION..................................................... 875 ERROR CODE [DAQSKR]......................................................................................... 876 S-NET COMMUNICATION FAILURE BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER........................... 876 ERROR CODE [DBQSKR]......................................................................................... 878 S-NET COMMUNICATION FAILURE BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER......................... 878 ERROR CODE [DB9SKR]......................................................................................... 880 S-NET COMMUNICATION FAILURE BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER......................... 880 ERROR CODE [DD15LD]......................................................................................... 882 MONITOR PANEL MODE SELECTOR SWITCH 1 [n] (PANEL SW1) INPUT ERROR........................................ 882 ERROR CODE [DD16LD]......................................................................................... 884 MONITOR PANEL MODE SELECTOR SWITCH 1 [‡] (PANEL SW2) INPUT ERROR........................................ 884 ERROR CODE [DD17LD]......................................................................................... 886 MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SW3) INPUT ERROR........................................ 886 ERROR CODE [DD18LD]......................................................................................... 888 MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SW4) INPUT ERROR........................................ 888 ERROR CODE [DD1CLD]......................................................................................... 890 SUB-TOTAL SWITCH FAILURE................................................................................ 890 ERROR CODE [DDS5L6]......................................................................................... 892 DECREASED STEERING OIL PRESSURE......................................................................... 892 ERROR CODE [DDY0LD]......................................................................................... 894 CANCEL SWITCH FAILURE................................................................................... 894 ERROR CODE [DGE2KX]......................................................................................... 896 ENGINE COOLANT TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE..................................... 896 ERROR CODE [DGE3L6]......................................................................................... 898 ABNORMAL CONNECTION OF ENGINE COOLANT TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM....................... 898 ERROR CODE [DGH2KX]......................................................................................... 900 HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE......................................................... 900 ERROR CODE [DGT1KX]......................................................................................... 901 TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE.................................................. 901 ERROR CODE [DHE4L6]......................................................................................... 902 ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE............................................................... 902 ERROR CODE [DHPCKX]......................................................................................... 904 BOTTOM PRESSURE SENSOR FAILURE.......................................................................... 904 ERROR CODE [DHPDKX]......................................................................................... 906 HEAD PRESSURE SENSOR FAILURE............................................................................ 906 ERROR CODE [DKA0KX]......................................................................................... 908 LIFT ARM ANGLE SENSOR FAILURE........................................................................... 908 ERROR CODE [DV00KB]......................................................................................... 910 SHORTED ALARM BUZZER OUTPUT SYSTEM...................................................................... 910 ERROR CODE [DY30ME]......................................................................................... 912 EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE............................................ 912 ACTION CODE [MON-1]......................................................................................... 914 PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON............... 914 ACTION CODE [MON-2]......................................................................................... 916 CIRCUIT DIAGNOSTIC PROCEDURES FOR ERROR CODE............................................................ 916 ACTION CODE [MON-3]......................................................................................... 918 BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT).... 918 ACTION CODE [MON-4]......................................................................................... 920 AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT...................................................... 920 ACTION CODE [MON-5]......................................................................................... 922 ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT......................................................... 922 ACTION CODE [MON-6]......................................................................................... 923 ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT............................................................ 923 ACTION CODE [MON-7]......................................................................................... 924 ENGINE COOLANT TEMPERATURE CAUTION LAMP DOES NOT LIGHT.................................................. 924 ACTION CODE [MON-8]......................................................................................... 926 COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT............................................................... 926 ACTION CODE [MON-9]......................................................................................... 927 HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT................................................... 927 ACTION CODE [MON-10]........................................................................................ 928 TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT............................................ 928 ACTION CODE [MON-11]........................................................................................ 930 STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT.......................................................... 930 ACTION CODE [MON-12]........................................................................................ 932 INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1).................................................. 932 ACTION CODE [MON-13]........................................................................................ 934 INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2).................................................. 934 ACTION CODE [MON-14]........................................................................................ 936 INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3).................................................. 936 ACTION CODE [MON-15]........................................................................................ 938 INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4).................................................. 938 ACTION CODE [MON-16]........................................................................................ 940 DEFECTIVE SUBTOTAL SWITCH............................................................................... 940 ACTION CODE [MON-17]........................................................................................ 942 DEFECTIVE CANCEL SWITCH................................................................................. 942 ACTION CODE [MON-18]........................................................................................ 944 DEFECTIVE BOTTOM PRESSURE SENSOR (SHORT FAULT).......................................................... 944 ACTION CODE [MON-19]........................................................................................ 946 DEFECTIVE HEAD SENSOR................................................................................... 946 ACTION CODE [MON-20]........................................................................................ 948 ALARM BUZZER DOES NOT SOUND OR STOP..................................................................... 948 30 DISASSEMBLY AND ASSEMBLY......................................................................................... 951 METHOD OF USING MANUAL.......................................................................................... 954 PRECAUTIONS WHEN PERFORMING SERVICE OPERATIONS.................................................................. 955 SPECIAL TOOL LIST............................................................................................... 958 SKETCH OF SPECIAL TOOLS..................................................................................... 961 CONNECTOR REPAIR PROCEDURES..................................................................................... 975 STRIPPING INSULATION........................................................................................ 975 WIRE INSPECTION............................................................................................. 975 CONTACT TERMINAL REMOVAL (HD30 TYPE)........................................................................ 976 CRIMPING CONTACT TERMINAL (HD30 TYPE)....................................................................... 977 INSERTION OF CONTACT TERMINAL (HD30 TYPE)................................................................... 978 CONTACT TERMINAL REMOVAL (DT TYPE).......................................................................... 979 CRIMPING CONTACT TERMINAL (DT TYPE)......................................................................... 980 INSERTION OF CONTACT TERMINAL (DT TYPE)..................................................................... 981 ENGINE.......................................................................................................... 982 ALTERNATOR.................................................................................................. 982 CYLINDER HEAD............................................................................................... 982 DAMPER...................................................................................................... 982 ENGINE OIL COOLER........................................................................................... 982 ENGINE FRONT SEAL........................................................................................... 982 ENGINE REAR SEAL............................................................................................ 982 FUEL INJECTION PUMP FOR LEFT BANK........................................................................... 982 FUEL INJECTION PUMP FOR RIGHT BANK.......................................................................... 982 NOZZLE HOLDER............................................................................................... 982 STARTING MOTOR.............................................................................................. 982 TURBOCHARGER................................................................................................ 982 WATER PUMP.................................................................................................. 982 REMOVAL..................................................................................................... 983 INSTALLATION................................................................................................ 987 RADIATOR FAN MOTOR.............................................................................................. 988 REMOVAL..................................................................................................... 988 INSTALLATION................................................................................................ 989 AFTERCOOLER..................................................................................................... 990 REMOVAL..................................................................................................... 990 INSTALLATION................................................................................................ 990 FAN AND FAN MOTOR............................................................................................... 991 REMOVAL..................................................................................................... 991 INSTALLATION................................................................................................ 992 FUEL TANK....................................................................................................... 993 REMOVAL..................................................................................................... 993 INSTALLATION................................................................................................ 995 PARKING BRAKE DISC PLATE........................................................................................ 996 REMOVAL..................................................................................................... 996 INSTALLATION................................................................................................ 998 TORQUE CONVERTER AND TRANSMISSION...............................................................................1000 REMOVAL.....................................................................................................1000 INSTALLATION................................................................................................1004 BLEEDING THE HYDRAULIC BRAKE CIRCUIT........................................................................1005 TRANSMISSION....................................................................................................1006 DISASSEMBLY.................................................................................................1006 ASSEMBLY....................................................................................................1014 TRANSMISSION CLUTCH PACK........................................................................................1023 DISASSEMBLY.................................................................................................1023 FORWARD AND REVERSE CLUTCH PACKS........................................................................1023 1ST AND 4TH CLUTCH PACK.................................................................................1025 2ND AND 3RD CLUTCH PACK.................................................................................1028 ASSEMBLY....................................................................................................1031 FORWARD AND REVERSE CLUTCH PACKS........................................................................1031 1ST AND 4TH CLUTCH PACK.................................................................................1034 2ND AND 3RD CLUTCH PACK.................................................................................1038 PARKING BRAKE...................................................................................................1043 DISASSEMBLY.................................................................................................1043 ASSEMBLY....................................................................................................1046 TORQUE CONVERTER (STANDARD).....................................................................................1051 DISASSEMBLY.................................................................................................1051 ASSEMBLY....................................................................................................1053 TORQUE CONVERTER (LOCK-UP)......................................................................................1056 DISASSEMBLY.................................................................................................1056 ASSEMBLY....................................................................................................1059 REAR AXLE.......................................................................................................1063 REMOVAL.....................................................................................................1063 INSTALLATION................................................................................................1065 FRONT AXLE......................................................................................................1067 REMOVAL.....................................................................................................1067 INSTALLATION................................................................................................1068 AXLE HOUSING....................................................................................................1069 DISASSEMBLY.................................................................................................1069 ASSEMBLY....................................................................................................1074 DIFFERENTIAL....................................................................................................1080 DISASSEMBLY.................................................................................................1080 ASSEMBLY....................................................................................................1086 CENTER HINGE PIN................................................................................................1097 REMOVAL.....................................................................................................1097 INSTALLATION................................................................................................1102 CAB.............................................................................................................1107 REMOVAL.....................................................................................................1107 INSTALLATION................................................................................................1109 CAB AND FLOOR FRAME.............................................................................................1110 REMOVAL.....................................................................................................1110 INSTALLATION................................................................................................1113 TRANSMISSION, WORK EQUIPMENT, PPC PUMP..........................................................................1114 REMOVAL.....................................................................................................1114 INSTALLATION................................................................................................1114 STEERING, SWITCHING, AND FAN PUMP...............................................................................1115 REMOVAL.....................................................................................................1115 INSTALLATION................................................................................................1115 STEERING DEMAND VALVE...........................................................................................1116 REMOVAL.....................................................................................................1116 INSTALLATION................................................................................................1117 DISASSEMBLY.................................................................................................1118 ASSEMBLY....................................................................................................1122 ORBITROL VALVE..................................................................................................1126 REMOVAL.....................................................................................................1126 INSTALLATION................................................................................................1127 DISASSEMBLY.................................................................................................1128 ASSEMBLY....................................................................................................1131 CONTROL SIDE............................................................................................1131 ECSS VALVE......................................................................................................1136 REMOVAL.....................................................................................................1136 INSTALLATION................................................................................................1136 WORK EQUIPMENT VALVE............................................................................................1137 REMOVAL.....................................................................................................1137 INSTALLATION................................................................................................1139 HYDRAULIC CYLINDERS.............................................................................................1140 STEERING, LIFT, AND BUCKET..................................................................................1140 DISASSEMBLY.................................................................................................1141 ASSEMBLY....................................................................................................1144 HYDRAULIC TANK..................................................................................................1150 REMOVAL.....................................................................................................1150 INSTALLATION................................................................................................1151 WORK EQUIPMENT..................................................................................................1152 REMOVAL.....................................................................................................1152 INSTALLATION................................................................................................1155 COUNTERWEIGHT...................................................................................................1157 REMOVAL.....................................................................................................1157 INSTALLATION................................................................................................1157 AIR CONDITIONER.................................................................................................1158 REMOVAL.....................................................................................................1158 INSTALLATION................................................................................................1161 AIR CONDITIONER COMPRESSOR......................................................................................1162 REMOVAL.....................................................................................................1162 INSTALLATION................................................................................................1162 OPERATOR’S SEAT.................................................................................................1163 DISASSEMBLY.................................................................................................1163 ASSEMBLY....................................................................................................1171 90 OTHERS...........................................................................................................1177 POWER TRAIN OIL CIRCUIT DIAGRAM.................................................................................1178 WITHOUT TORQUE CONVERTER LOCKUP CLUTCH......................................................................1178 WITH TORQUE CONVERTER LOCKUP CLUTCH.........................................................................1179 BRAKE OIL CIRCUIT DIAGRAM.......................................................................................1180 HYDRAULIC CIRCUIT SCHEMATIC.....................................................................................1182 ELECTRICAL SCHEMATIC............................................................................................1184 STANDARD....................................................................................................1184 FLOOR HARNESS - CAB.....................................................................................1184 FLOOR HARNESS - TRANSMISSION CONTROLLER.................................................................1186 FLOOR HARNESS - TRANSMISSION HARNESS....................................................................1188 FLOOR HARNESS - REAR HARNESS............................................................................1190 FLOOR HARNESS - RELAY UNITS.............................................................................1192 WITH JOYSTICK STEERING......................................................................................1194 FLOOR HARNESS - CAB.....................................................................................1194 FLOOR HARNESS - TRANSMISSION CONTROLLER.................................................................1196 FLOOR HARNESS - JOYSTICK HARNESS........................................................................1198 FLOOR HARNESS - TRANSMISSION HARNESS....................................................................1200 FLOOR HARNESS - REAR HARNESS............................................................................1202 FLOOR HARNESS - RELAY UNITS.............................................................................1204 ENGINE HARNESS..............................................................................................1206 REAR HARNESS................................................................................................1208 FRONT FRAME HARNESS.........................................................................................1210 CAB HARNESS.................................................................................................1212 MONITOR PANEL CONTROLLER....................................................................................1214 A/C RELAY HARNESS...........................................................................................1216 TRANSMISSION HARNESS........................................................................................1218 JOYSTICK CONTROLLER HARNESS.................................................................................1220 KOMTRAX HARNESS.............................................................................................1222
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3 reviews for Komatsu WA400-5L WHEEL LOADER SERVICE REPAIR MANUAL (SN: A40001 & up) – PDF Download
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