Komatsu WA400L-Series Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu WA400L-Series Wheel Loaders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu WA400L-Series Wheel Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,511 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM009601 - Wheel Loader GALEO WA400-5L Operation & Maintenance Manual.pdf
CEBM010002 - Wheel Loader WA400-5L Shop Manual.pdf
MAIN SECTIONS
CEAM009601 - Wheel Loader GALEO WA400-5L Operation & Maintenance Manual......2
COVER......2
INTRODUCTION......3
FOREWORD......4
SAFETY INFORMATION......5
APPROVED AND NON-APPROVED USES......6
NON-APPROVED......6
PRODUCT IDENTIFICATION......7
MACHINE SERIAL NUMBER......7
ENGINE SERIAL NUMBER AND EMISSION LABEL......8
SERVICE METER LOCATION......8
SERIAL NUMBERS AND DEALER INFORMATION......9
CONTENTS......10
SAFETY......23
GENERAL SAFETY RULES AND PRECAUTIONS......24
GENERAL SAFETY RULES......24
SAFETY FEATURES......25
PERSONAL PROTECTIVE EQUIPMENT......25
UNAUTHORIZED MODIFICATIONS......26
LEAVING OPERATOR’S COMPARTMENT......26
MOUNTING AND DISMOUNTING......27
WASTE HANDLER APPLICATIONS......27
FIRE PREVENTION FOR FUEL AND OIL......28
DUST HAZARD PRECAUTIONS......28
CRUSH OR PINCH POINT DANGERS......29
FIRE EXTINGUISHER AND FIRST AID KIT......29
INSIDE OPERATOR’S COMPARTMENT......30
PRECAUTIONS WHEN USING ROPS......30
PRECAUTIONS FOR ATTACHMENTS......30
STARTING YOUR WORK OPERATIONS......31
WORK SITE HAZARDS......31
AVOIDING DANGEROUS SITUATIONS......31
WORKING CLEARANCES......33
RULES FOR ROAD TRAVEL......34
TRAVELING IN REVERSE......34
TRAVELING ON ICY OR SNOW-COVERED SURFACES......34
WORKING ON LOOSE OR UNSTABLE GROUND......34
TRAVEL ON SLOPES......35
PARKING THE MACHINE......36
PRECAUTIONS DURING MAINTENANCE OPERATIONS......37
WARNING TAGS......37
EQUIPMENT STORAGE......37
WORKING UNDER THE MACHINE......38
USING DROP LAMPS......38
KEEPING THE MACHINE CLEAN......39
RUNNING THE MACHINE DURING MAINTENANCE......39
RULES FOR REFUELING THE MACHINE......40
COOLING SYSTEM PRECAUTIONS......40
BATTERY PRECAUTIONS......41
STARTING THE MACHINE......41
HIGH PRESSURE HOSES......42
HIGH TEMPERATURES AREAS......42
DISPOSAL OF WASTE MATERIALS......42
INFLATING TIRES......43
ACCUMULATOR......43
CRITICAL PARTS......43
VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED......43
SAFETY AND WARNING DECALS......44
LOCATION OF THE SAFETY DECALS......44
LOCATION OF SAFETY LABELS......45
SAFETY LABELS......45
OPERATION......53
GENERAL VIEW OF MACHINE......54
OUTSIDE VIEW OF THE MACHINE......54
INSIDE VIEW OF THE CAB......55
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS......56
INSTRUMENT BEZEL......56
SWITCH PANELS......57
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM......58
INSTRUMENT BEZEL......58
TYPES OF WARNING......59
MACHINE ELECTRONIC MONITORING DISPLAY......60
MONITOR MODE SELECTOR SWITCHES......60
MODE SELECTOR SWITCH 1......61
MODE SELECTOR SWITCH 2......61
MONITOR DISPLAY INFORMATION......61
HOUR METER AND ODOMETER DISPLAY......61
ADJUSTING MONITOR BRIGHTNESS......62
PROGRAMMING TELEPHONE NUMBER......62
ACTION CODE DISPLAY......62
FAILURE CODE DISPLAY......63
SERVICE DISPLAY......64
SELECTING LANGUAGE......65
EMERGENCY STOP WARNING SYSTEM......66
BRAKE PRESSURE WARNING LAMP......66
ENGINE OIL PRESSURE WARNING LAMP......67
BATTERY CHARGE WARNING LAMP......67
STEERING OIL PRESSURE WARNING LAMP......67
CAUTION ALERT WARNING SYSTEM......68
AXLE OIL TEMPERATURE CAUTION LAMP......68
TORQUE CONVERTER CAUTION LAMP......69
COOLANT TEMPERATURE CAUTION LAMP......69
HYDRAULIC OIL TEMPERATURE CAUTION LAMP......69
FUEL LEVEL CAUTION LAMP......69
INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM......70
ENGINE OIL LEVEL CAUTION LAMP......70
RADIATOR COOLANT LEVEL CAUTION LAMP......71
AIR CLEANER CLOGGING CAUTION LAMP......71
MAINTENANCE CAUTION LAMP......71
MODE ALERT LAMPS......72
PARKING BRAKE PILOT LAMP......72
COOLING FAN REVERSE ROTATION PILOT LAMP......73
EMERGENCY STEERING PILOT LAMP......73
OUTPUT MODE PILOT LAMP (POWER MODE)......73
PREHEATING PILOT LAMP......74
JOYSTICK PILOT LAMP......74
SHIFT INDICATOR......74
AUTO-SHIFT PILOT LAMP......74
LOCKUP PILOT LAMP......75
SHIFT HOLD PILOT LAMP......75
SHIFT LEVER POSITION PILOT LAMP......75
TURN SIGNAL PILOT LAMP......75
HEAD LAMP HIGH BEAM PILOT LAMP......76
GAUGE DISPLAY......77
TORQUE CONVERTER OIL TEMPERATURE GAUGE......77
ENGINE TEMPERATURE GAUGE......78
HYDRAULIC TEMPERATURE GAUGE......78
FUEL GAUGE......78
SPEEDOMETER......78
METER DISPLAY PILOT LAMP......79
MACHINE MONITOR......79
DISPLAYING ODOMETER......79
RESET FOR FILTER, OIL REPLACEMENT TIME......79
ENTERING A TELEPHONE NUMBER......80
SELECTING A LANGUAGE......81
ADJUSTING MONITOR BRIGHTNESS......82
MACHINE SWITCHES AND CONTROLS......83
SWITCH LOCATION......83
IGNITION SWITCH......84
POWER MODE SELECTOR SWITCH......84
TRANSMISSION MODE SELECTOR SWITCH......85
TRANSMISSION CUT-OFF SWITCH......85
TRANSMISSION CUT-OFF SET SWITCH......86
LAMP SWITCH......86
TURN SIGNAL LEVER......86
DIMMER SWITCH......87
HORN BUTTON......87
HAZARD LAMP SWITCH......87
PARKING BRAKE SWITCH......87
FRONT WORKING LAMP SWITCH......88
REAR WORKING LAMP SWITCH......88
MONITOR PANEL MODE SELECTOR SWITCH 1......89
MONITOR PANEL MODE SELECTOR SWITCH 2......89
KICKDOWN SWITCH......89
HOLD SWITCH......90
FRONT WIPER SWITCH......90
REAR WIPER SWITCH......90
CIGARETTE LIGHTER......91
CAB LAMP SWITCH......91
REAR DEFROSTER SWITCH......91
E.C.S.S. SWITCH......92
EMERGENCY STEERING SWITCH......92
COOLING FAN REVERSE ROTATION SWITCH......93
TORQUE CONVERTER LOCK-UP SWITCH......93
LOAD METER CANCEL SWITCH......93
LOAD METER SUBTOTAL SWITCH......93
SOUND SYSTEM......94
DIGITAL ESPERIA RADIO COMPONENTS......94
POWER SWITCH/VOLUME......94
TONE CONTROL KNOB......95
DISPLAY......95
CLOCK BUTTON/DISPLAYING FREQUENCY......95
AST......95
PRESET BUTTON......96
SEEK......96
BAND SELECTOR SWITCH......96
TUNING SWITCH......96
LISTENING TO THE RADIO......97
AUTOMATIC TUNING......97
MANUAL TUNING......97
SETTING THE PRESET BUTTONS......97
AUTOMATIC MEMORY......98
AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO......98
ADJUSTING THE TIME......98
BLAUPUNKT CALAIS RADIO COMPONENTS......99
POWER SWITCH/MUTE......99
VOLUME CONTROL......100
FMT CONTROL......100
IR REMOTE CONTROL (OPTIONAL)......100
RDS CONTROL......100
ML CONTROL......101
EJECT CASSETTE......101
CASSETTE COMPARTMENT......101
FF AND RW BUTTONS......101
GEO BUTTON......102
SRC BUTTON......102
AUDIO BUTTON......102
MULTIFUNCTION ROCKER SWITCH......102
MENU BUTTON......103
KEYPAD 1-5......103
TRAFFIC......103
DISPLAY......103
THEFT PROTECTION......104
PRECAUTIONS WHEN USING......104
AIR CONDITIONER CONTROL PANEL......105
FAN SWITCH......105
AIR CONDITIONER SWITCH......106
MODE SELECTOR SWITCH......106
FRESH/RECIRC SELECTOR SWITCH......106
EXTERNAL AIR INTAKE......106
TEMPERATURE CONTROL SWITCH......107
METHOD OF OPERATION......107
WHEN NOT USING THE AIR CONDITIONER REGULARLY......108
COOL BOX......109
PRECAUTIONS WHEN USING THE AIR CONDITIONER......109
CONTROL LEVERS, PEDALS......110
SPEED CONTROL LEVER......110
DIRECTIONAL LEVER......112
SPEED CONTROL LEVER STOPPER......112
SAFETY LOCK LEVER......113
BUCKET CONTROL LEVER......113
LIFT ARM CONTROL LEVER......114
BRAKE PEDAL......114
ACCELERATOR PEDAL......115
STEERING TILT LOCK LEVER......115
SECURITY AND LOCKS......116
IGNITION KEY LOCKED AREAS......116
CAB DOOR LOCKS......116
ENGINE ACCESS DOORS......116
REAR GRILL......117
FUEL CAP......117
PADLOCKED AREAS......118
BATTERY AND TOOL BOX......118
TRANSFER CASE......118
UPPER HOOD ACCESS PANEL......118
SAFETY FEATURES......119
PASSIVE SAFETY FEATURES......119
ROLL-OVER PROTECTIVE STRUCTURE (ROPS)......119
CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY)......119
BACKUP WARNING ALARM......119
ACTIVE SAFETY FEATURES......120
SAFETY BAR......120
SEAT BELT......120
EQUIPMENT LOCK LEVER......121
MACHINE FEATURES......122
CAB DOORS......122
OPEN LOCK......122
ELECTRICAL......122
FUSE......122
FUSE CAPACITY AND NAME OF CIRCUIT......123
SLOW BLOW FUSE......124
AUXILIARY POWER......124
MACHINE CAB AND CHASSIS......125
SEAT ADJUSTMENT......125
HANDLING CAB WIPER......127
DUST INDICATOR......127
GREASE PUMP......127
PRECAUTIONS BEFORE STARTING WORK OPERATIONS......128
PRE-OPERATIONAL CHECKS......128
PERFORM A WALK AROUND CHECK OF YOUR MACHINE......128
UNDER THE HOOD......128
CHECK COOLANT LEVEL......129
CHECK ENGINE OIL LEVEL, ADD OIL......130
REAR-VIEW MIRROR ADJUSTMENT......130
IN THE OPERATOR’S CAB......131
SEAT BELT ADJUSTMENT......131
LEVER STAND ADJUSTMENT......132
LEVER STAND ANGLE ADJUSTMENT......132
START-UP PROCEDURES......133
CHECK FUEL LEVEL, ADD FUEL......133
CHECK THE BRAKE PEDALS......134
CHECK THE PARKING BRAKE......134
STARTING THE ENGINE......135
OPERATIONS AND CHECKS AFTER STARTING ENGINE......138
BREAKING IN THE MACHINE......138
NORMAL START-UP AND WARM-UP......138
STOPPING THE ENGINE......139
TRAVELING, STOPPING AND PARKING THE MACHINE......140
TRAVELING......140
TURNING ON SLOPES......142
CHANGING GEAR SPEED RANGES......142
CHANGING DIRECTION......143
WHEN USING AUTO-SHIFT......144
STOPPING AND PARKING THE MACHINE......145
TRANSMISSION CUT-OFF SWITCH......147
ADJUSTING THE TRANSMISSION CUT-OFF......147
STOPPING WHEN TRANSMISSION CUT-OFF IS ON......148
TURNING......148
EMERGENCY STEERING......149
USING THE EMERGENCY STEERING......149
EMERGENCY STEERING SELF-CHECK FUNCTION......150
STARTING YOUR WORK OPERATIONS......151
WORK EQUIPMENT......151
LIFT ARM LEVER......151
BUCKET LEVER......152
SCOOPING A LOAD OR CUTTING A GRADE......153
LOADING PILED SOIL OR BLASTED ROCK......153
CUTTING A GRADE ON LEVEL GROUND......155
LEVELING OPERATIONS......156
PUSHING OPERATION......156
LOAD AND CARRY OPERATIONS......156
LOADING OPERATIONS......157
CROSS DRIVE LOADING......157
V-SHAPE LOADING......157
PRECAUTIONS WHEN PILING UP LOADS......157
LOADING TRUCKS OR HOPPERS......158
PRECAUTIONS DURING OPERATION......159
PERMISSIBLE WATER DEPTH......159
IF WHEEL BRAKE DOES NOT WORK......159
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES......159
BRAKING ON DOWNHILL SLOPE......159
IF THE ENGINE STOPS......159
PRECAUTIONS WHEN DRIVING THE MACHINE......160
PRECAUTIONS REGARDING BRAKE FUNCTION......160
WORK EQUIPMENT AND MACHINE POSTURE......161
ADJUSTING BUCKET......161
BOOM KICKOUT ADJUSTMENT......161
BUCKET POSITIONER ADJUSTMENT......162
BUCKET LEVEL INDICATOR......162
TRANSPORTING THE MACHINE......163
LOADING AND SECURING THE MACHINE......163
LIFTING THE MACHINE......164
LIFTING LOCATIONS AND PROCEDURES......164
USING WIRE ROPE......165
PRE LIFTING PROCEDURES......165
TOWING THE MACHINE......167
COLD WEATHER OPERATION......168
FUEL AND LUBRICANTS......168
COOLANT......168
PRECAUTIONS AFTER COMPLETION OF WORK......168
AFTER COLD WEATHER......168
WARMING UP THE STEERING......168
MAINTENANCE......169
GUIDES TO MAINTENANCE......170
CHECK SERVICE METER......170
KOMATSU GENUINE REPLACEMENT PARTS......170
KOMATSU GENUINE OILS......170
ALWAYS USE CLEAN WASHER FLUID......170
ALWAYS USE CLEAN OIL AND GREASE......170
CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS......170
FUEL STRAINER......170
WELDING INSTRUCTIONS......170
DO NOT DROP THINGS INSIDE THE MACHINE......171
DUSTY WORKSITES......171
AVOID MIXING OIL......171
LOCKING INSPECTION COVERS......171
BLEEDING AIR FROM HYDRAULIC CIRCUIT......171
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES......171
CHECKS AFTER INSPECTION AND MAINTENANCE......172
SYSTEMS TROUBLESHOOTING CHARTS......173
ELECTRICAL SYSTEM......173
CHASSIS......174
ENGINE......178
OUTLINES OF SERVICE......180
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......180
OIL......180
FUEL......180
COOLANT......180
GREASE......181
PERFORMING KOWA (Komatsu Oil Wear Analysis)......181
KOWA ANALYSIS ITEMS......182
OIL SAMPLING......182
STORING OIL AND FUEL......182
FILTERS......183
OUTLINE OF ELECTRIC SYSTEM......183
WEAR PARTS LIST......184
FUEL, COOLANT AND LUBRICANTS......185
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS......185
STANDARD TIGHTENING TORQUES FOR FASTENERS AND HOSES......187
TORQUE LIST......187
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......189
MAINTENANCE SCHEDULE CHART......190
GENERAL MAINTENANCE AND INSPECTION......192
INITIAL 250 HOURS SERVICE......192
CHANGE TRANSMISSION OIL FILTER CARTRIDGE......192
REPLACE HYDRAULIC TANK FILTER ELEMENT......192
WHEN REQUIRED......192
CLEANING THE MACHINE......192
ENGINE AIR FILTER......194
CLEANING THE COOLING SYSTEM......197
WATER SEPARATOR......199
TRANSMISSION OIL LEVEL......201
AXLE OIL LEVEL......202
CHECK AXLE VENT......204
AIR CONDITIONER CONDENSER......204
WINDOW WASHING FLUID LEVEL......205
CLEAN RADIATOR FINS......206
CHECK ELECTRICAL INTAKE AIR HEATER......209
REPLACE BOLT-ON CUTTING EDGE......209
REPLACE BUCKET TEETH......210
REPLACING SLOW-BLOW FUSE......211
INSPECTION OF TIRES......212
EVERY SPECIFIC HOURS SERVICE......214
EVERY 50 HOURS OF SERVICE......214
DRAIN SEDIMENT FROM FUEL TANK......214
EVERY 100 HOURS SERVICE......214
LUBRICATE THE REAR AXLE PIVOT PIN......214
CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL......214
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT......215
EVERY 250 HOURS OF SERVICE......216
CHECK BATTERY ELECTROLYTE LEVEL......216
CHECK PARKING BRAKE......218
ALTERNATOR BELT TENSION......218
AIR CONDITIONER COMPRESSOR BELT TENSION......218
WHEEL HUB NUTS......219
AIR CONDITIONER RECIRCULATION FILTER......219
LUBRICATING POINTS......220
EVERY 500 HOURS SERVICE......221
CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE......221
REPLACING FUEL FILTER CARTRIDGE......222
EVERY 1000 HOURS SERVICE......223
CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER......223
CLEAN THE TRANSMISSION CASE VENT......224
LUBRICATING POINTS......225
CHECKING PARTS OF TURBOCHARGER......225
REPLACE CORROSION RESISTOR CARTRIDGE......225
EVERY 2000 HOURS SERVICE......226
CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT......226
HYDRAULIC TANK VENT ELEMENT......228
CHANGE THE AXLE OIL......229
AIR CONDITIONER RECIRCULATION FILTER......229
CLEAN PPC CIRCUIT STRAINER......230
CLEAN THE ENGINE VENT ELEMENT......230
CHECK ALTERNATOR, STARTER MOTOR......231
CHECK ENGINE VALVE CLEARANCE......231
CHECK TURBOCHARGER......231
CHECK INJECTOR......231
CHECK ACCUMULATOR GAS PRESSURE......231
CHECK VIBRATION DAMPER......231
CHECKING BRAKE DISC WEAR......232
EVERY 4000 HOURS SERVICE......233
LUBRICATING POINTS......233
CHECK WATER PUMP......234
CHECK AIR CONDITIONER COMPRESSOR......234
REPLACE INJECTOR NOZZLE TIP......234
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER......234
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......234
EVERY 8000 HOURS SERVICE......235
REPLACE HIGH-PRESSURE PIPING CLAMP......235
REPLACE FUEL SPRAY PREVENTION CAP......235
LONG-TERM STORAGE......236
BEFORE STORAGE......236
DURING STORAGE......236
AFTER STORAGE......236
TROUBLESHOOTING EMERGENCY PROBLEMS......237
WHEN MACHINE RUNS OUT OF FUEL......237
PROCEDURE FOR BLEEDING AIR......237
TOWING THE MACHINE......238
WHEN ENGINE CAN BE USED......239
WHEN ENGINE CANNOT BE USED......239
RELEASING THE PARKING BRAKE......239
RELEASE PARKING BRAKE WITH EMERGENCY PARKING BRAKE RELEASE VALVE......239
MECHANICAL RELEASE......241
EMERGENCY TRAVEL OPERATION......242
SPECIFICATIONS......243
SPECIFICATIONS......244
MACHINE DIMENSIONS AND WEIGHTS......244
TIRES......244
WORK EQUIPMENT......245
WEIGHT CHANGES......245
MACHINE SYSTEMS SPECIFICATIONS......246
ENGINE......246
OPTIONS, ATTACHMENTS......247
MONITOR WITH LOAD METER......248
LOAD METER......248
SWITCHES......248
LOAD METER CANCEL SWITCH......249
LOAD METER SUB TOTAL SWITCH......249
LOAD METER FUNCTIONS......250
LOAD METER ADDITION MODE......250
LOAD METER REMAIN MODE......251
SELECTION OF DISPLAY FOR TYPE OF LOAD......251
METHOD OF CALIBRATION (ADJUSTING 0 POINT)......252
DELETING LOAD METER DISPLAY......252
SPEED DISPLAY......252
USING LOAD METER DISPLAY......253
SETTING ADDITION MODE......253
SETTING THE REMAIN MODE......254
TOTAL LOAD DATA DISPLAY......256
STOPPING THE CALCULATION......257
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY......258
PERFORMING CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED......259
SUBTRACTION FUNCTION......261
SETTING THE TIME ON THE CLOCK......264
PRINTER OUTPUT......266
PRINTOUT MODE......266
SELECTING THE PRINTOUT MODE......267
TORQUE CONVERTER LOCK-UP......268
GENERAL LOCATIONS......268
TORQUE CONVERTER LOCK-UP SWITCH......268
TORQUE CONVERTER LOCK-UP PILOT LAMP......269
METHOD OF OPERATION......269
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED......270
TRAVEL SPEED WARNING FUNCTION......270
TRAVEL SPEED LIMIT FUNCTION......270
WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM......271
FAN SYSTEM OPERATION......271
MODE SELECTOR SWITCH......272
FORWARD/REVERSE TIMER......272
REVERSE/FORWARD INDICATOR LAMPS......272
FORWARD SETTING KNOB......273
REVERSE SETTING KNOB......273
FORWARD TIME UNIT SELECTOR SWITCH......274
SCALE FIGURE SELECTOR SWITCH......274
DIRECTION SELECTOR SWITCH......275
REVERSE PILOT LAMP......275
CONTROL BOX......275
CLEANING RADIATOR AND COOLER FINS......276
HANDLING JOYSTICK STEERING SYSTEM......278
EXPLANATION OF COMPONENTS......278
SHIFT UP, SHIFT DOWN SWITCHES......278
FNR SWITCH......279
JOYSTICK STEERING LEVER......279
JOYSTICK ON/OFF SWITCH......279
HI/LOW SELECTOR SWITCH......279
HORN SWITCH......280
CONSOLE LOCK LEVER......280
HEIGHT ADJUSTMENT LOCK LEVER......280
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER......280
STRUCTURE AND FUNCTION OF JOYSTICK STEERING......281
JOYSTICK AND STEERING WHEEL OPERATION......282
GETTING IN OR OUT OF THE OPERATOR'S CAB......282
JOYSTICK CONSOLE ADJUSTMENT......283
JOYSTICK OPERATION......283
SELECTING BUCKET AND TIRES......286
CEBM010002 - Wheel Loader WA400-5L Shop Manual......289
COVER......289
FOREWORD......290
CONTENTS......290
SAFETY......301
SAFETY NOTICE......301
GENERAL......303
HOW TO READ THE SHOP MANUAL......304
HOISTING INSTRUCTIONS......305
COATING MATERIALS......306
STANDARD TIGHTENING TORQUE......308
ELECTRIC WIRE CODE......310
CONVERSION TABLES......311
01 GENERAL......317
SPECIFICATIONS......318
WEIGHT TABLE......322
FUEL, COOLANT AND LUBRICANTS......324
GENERAL ASSEMBLY DRAWING......326
10 STRUCTURE AND FUNCTION......327
COOLING SYSTEM......333
SPECIFICATIONS......333
ENGINE MOUNT, TRANSMISSION MOUNT......334
POWER TRAIN......335
POWER TRAIN SYSTEM DIAGRAM......336
WITHOUT TORQUE CONVERTER LOCKUP CLUTCH......336
WITH TORQUE CONVERTER LOCK-UP CLUTCH......337
OUTLINE......339
DRIVE SHAFT (PROPELLER SHAFT)......340
OUTLINE......340
TORQUE CONVERTER, TRANSMISSION PIPING......341
TORQUE CONVERTER......342
WITHOUT LOCK-UP CLUTCH......342
PATH OF POWER TRANSMISSION......344
POWER FLOW......344
OIL FLOW......344
WITH LOCK-UP CLUTCH......345
PATH OF POWER TRANSMISSION......348
LOCK-UP CLUTCH DISENGAGED......348
LOCK-UP CLUTCH ENGAGED......348
OIL FLOW......349
TRANSMISSION......350
OUTLINE......354
F AND R CLUTCHES: WITHOUT LOCK-UP CLUTCH......355
F AND R CLUTCHES: WITH LOCK-UP CLUTCH......356
1ST AND 4TH CLUTCH......357
2ND AND 3RD CLUTCH......358
CLUTCH OPERATION......359
CLUTCH ENGAGED......359
CLUTCH DISENGAGED......359
FORWARD 1ST......360
OPERATION......360
FORWARD 2ND......361
OPERATION......361
FORWARD 3RD......362
OPERATION......362
FORWARD 4TH......363
OPERATION......363
REVERSE 1ST......364
OPERATION......364
TRANSMISSION CONTROL VALVE......365
WITHOUT LOCK-UP CLUTCH......365
OUTLINE......366
WITH LOCK-UP CLUTCH......367
OUTLINE......368
ELECTRONIC CONTROL MODULATION VALVE (ECMV)......369
ECMV FOR SPEED CLUTCH......370
OUTLINE......370
ECMV AND PROPORTIONAL SOLENOID......370
ECMV AND FILL SWITCH......370
ECMV ACTUATION......371
ECMV FOR LOCK-UP CLUTCH......373
OUTLINE......373
OPERATION WHEN TRAVELING IN TORQUE CONVERTER DRIVE......373
WHEN TRAVELING IN DIRECT DRIVE (CHANGING FROM TORQUE CONVERTER DRIVE DIRECT DRIVE)......374
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE......375
OUTLINE......377
OPERATION......377
FLOW VALVE......378
OPERATION......378
AXLE......379
FRONT AXLE......379
REAR AXLE......380
DIFFERENTIAL......381
FRONT DIFFERENTIAL......381
REAR DIFFERENTIAL......383
OUTLINE......385
LIMITED SLIP DIFFERENTIAL......386
LIMITED SLIP DIFFERENTIAL OPERATION......390
FINAL DRIVE......392
OUTLINE......394
AXLE MOUNTING, CENTER HINGE PIN......395
OUTLINE......395
STEERING PIPING......399
STEERING COLUMN, ORBIT ROLL......400
STEERING VALVE......401
OVERLOAD RELIEF VALVE......403
FUNCTION......403
OPERATION......403
STEERING RELIEF VALVE......405
FUNCTION......405
STEERING RELIEF VALVE OPERATION......406
DEMAND VALVE OPERATION......407
FLOW AMP......410
STEERING VALVE OPERATION......414
NEUTRAL......414
TURNING RIGHT......415
TURNING LEFT......416
ORBIT-ROLL VALVE......417
OUTLINE......418
STRUCTURE......418
CONNECTION BETWEEN THE HAND PUMP AND SLEEVE......419
STOP VALVE......421
EMERGENCY STEERING PUMP......422
FUNCTION......422
EMERGENCY STEERING MOTOR......423
FUNCTION......423
STEERING CYLINDER......424
JOYSTICK STEERING......426
JOYSTICK PPC VALVE......427
FUNCTION......427
STEERING SWITCH VALVE......429
BRAKE PIPING......430
BRAKE VALVE......432
BRAKE VALVE - LEFT......432
BRAKE VALVE - RIGHT......434
OUTLINE......436
OPERATION......436
CHARGE VALVE......439
FUNCTION......440
OPERATION......441
PPC RELIEF VALVE......443
OUTLINE......443
OPERATION......443
ACCUMULATOR - BRAKE......444
FUNCTION......444
SPECIFICATIONS......444
FUNCTION......445
SPECIFICATIONS......445
BRAKE......446
FRONT......446
OUTLINE......447
REAR......448
OUTLINE......449
OPERATION......450
PARKING BRAKE CONTROL......451
OUTLINE......451
PARKING BRAKE......452
OUTLINE......452
PARKING BRAKE SOLENOID VALVE......454
OPERATION......455
PARKING BRAKE EMERGENCY RELEASE VALVE......456
OUTLINE......456
HYDRAULIC PIPING......457
OUTLINE......460
WORK EQUIPMENT CONTROL LEVER......461
FOR PPC VALVE......461
HYDRAULIC TANK......462
BREATHER......463
HYDRAULIC PUMPS......464
STEERING PUMP, SWITCH PUMP......464
OUTLINE......464
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS......466
OUTLINE......466
E.C.S.S......468
WORK EQUIPMENT CONTROL VALVE......470
2-SPOOL VALVE......470
3-SPOOL VALVE......473
RELIEF VALVE......476
FUNCTION......476
OPERATION......476
SAFETY-SUCTION VALVE......477
FUNCTION......477
OPERATION......477
SUCTION VALVE......478
FUNCTION......478
OPERATION......478
CUT-OFF VALVE......479
FUNCTION......479
WORK EQUIPMENT CONTROL VALVE OPERATION......481
NEUTRAL POSITION OF THE LIFT ARM AND BUCKET SPOOLS......481
RAISED POSITION FOR THE LIFT ARM SPOOL......482
LOWER POSITION OF THE LIFT ARM SPOOL......483
FLOAT POSITION OF THE LIFT ARM SPOOL......484
DUMP POSITION FOR THE BUCKET SPOOL......485
TILT POSITION FOR THE BUCKET SPOOL......486
WORK EQUIPMENT PPC VALVE......487
OPERATION......489
ATTACHMENT PPC VALVE......493
OPERATION......495
COOLING FAN MOTOR......497
MODEL: LMF28......497
HYDRAULIC MOTOR......499
SUCTION VALVE......500
OPERATION OF REVOLUTION DIRECTION CHANGEOVER VALVE......501
COOLING FAN MOTOR DRIVE PUMP......502
MODEL: LPV......502
SERVO VALVE......507
SAFETY VALVE......509
WORK EQUIPMENT LINKAGE......510
BUCKET......512
BUCKET POSITIONER, LIFT ARM KICK-OUT......513
BUCKET POSITIONER......514
LIFT ARM KICK-OUT......514
PROXIMITY SWITCH OPERATION......515
WHEN LIFT ARM IS RAISED......515
WHEN BUCKET IS TILTED......517
WORK EQUIPMENT CYLINDER......519
LIFT ARM CYLINDER......519
BUCKET CYLINDER......519
CAB......521
AIR CONDITIONER......522
AIR CONDITIONER PIPING......522
MACHINE MONITORING SYSTEM......523
OUTLINE......523
INDIVIDUAL CIRCUIT DIAGRAMS OF THE MACHINE MONITOR......525
STARTING AND LIGHTING FUNCTIONS......525
LOAD METER......525
SENSING FUNCTIONS......526
POWER SUPPLY AND NETWORK......527
AUTOMATIC PREHEATING FUNCTION......528
MACHINE MONITOR......530
STANDARD SPECIFICATIONS......530
LOAD METER SPECIFICATION......531
TABLE OF MONITOR INDICATION ITEMS......532
SETTING THE MACHINE MONITOR......539
SERVICE MODE FUNCTIONS......542
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRIC SYSTEM......545
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM......547
ITEMS RELATED TO MAINTENANCE MONITOR......548
REAL-TIME MONITORING FUNCTION......551
REAL-TIME MONITORING ITEMS......553
MACHINE SETTING......564
SETTING NECESSARY FOR OPTION MOUNTING......567
OPTIONAL DEVICE SETTING FOR MACHINE MONITOR......568
TRANSMISSION CONTROL SYSTEM......580
SYSTEM DIAGRAM......580
CONTROL FUNCTION......581
ELECTRIC CIRCUIT DIAGRAM (STANDARD)......598
TRANSMISSION CONTROLLER......602
WORK EQUIPMENT CONTROL SYSTEM......604
ELECTRIC CIRCUIT DIAGRAM......607
JOYSTICK OPTION ONLY......607
WORK EQUIPMENT CONTROLLER......609
JOYSTICK OPTION......609
ELECTRIC TRANSMISSION CONTROL......612
FUNCTION......613
COMBINATION SWITCH......614
FUNCTION......614
OPERATION......615
KICK DOWN, HOLD SWITCH......616
FUNCTION......616
ENGINE START CIRCUIT......617
FUNCTION......617
OPERATION......618
ENGINE STOP CIRCUIT......619
OPERATION......619
PREHEATING CIRCUIT......620
AUTOMATIC PREHEATING SYSTEM......620
OUTLINE......620
OPERATION......620
ENGINE POWER MODE SELECTOR CIRCUIT......621
FUNCTION......621
OPERATION......621
PARKING BRAKE CIRCUIT......622
OPERATION......622
SENSORS......626
ENGINE SPEED SENSOR......626
FUNCTION......626
ENGINE OIL PRESSURE SENSOR......627
FUNCTION......627
ENGINE OIL LEVEL SENSOR......627
FUNCTION......627
TEMPERATURE SENSOR......628
COOLANT (FOR MONITOR), TORQUE CONVERTER OIL, HYDRAULIC OIL, TRANSMISSION OIL, BRAKE OIL......628
COOLANT TEMPERATURE SENSOR - PREHEATING......628
FUNCTION......628
TRANSMISSION CUT-OFF PRESSURE SENSOR......629
FUNCTION......629
COOLANT LEVEL SENSOR......630
FUNCTION......630
FUEL LEVEL SENSOR......631
FUNCTION......631
BOOM ANGLE SENSOR FOR LOAD METER......632
FUNCTION......632
AIR CLEANER CLOGGING SENSOR......633
FUNCTION......633
LOAD METER PRESSURE SENSOR......634
FUNCTION......634
BATTERY FLUID LEVEL SENSOR......635
FUNCTION......635
RELAY......636
20 TESTING, ADJUSTING AND TROUBLESHOOTING......637
STANDARD VALUE TABLE FOR ENGINE......639
STANDARD VALUE TABLE FOR CHASSIS......640
SPECIAL TOOLS......647
ENGINE COMPONENTS......649
MEASURING EXHAUST SMOKE......649
MEASURING EXHAUST TEMPERATURE......649
ADJUSTING VALVE CLEARANCE......649
MEASURING COMPRESSION PRESSURE......649
MEASURING CRANCASE PRESSURE......649
MEASURING ENGINE OIL PRESSURE......649
MEASURING BOOST PRESSURE......649
MEASURING FUEL PRESSURE......649
ADJUSTING ENGINE SPEED SENSOR......649
BLEEDING AIR FROM FUEL SYSTEM......649
MEASURING ENGINE SPEED......650
ADJUSTING ACCELERATOR PEDAL......652
ADJUSTING THE POWER MODE......652
ADJUSTING THE NORMAL MODE......653
ADJUSTING TRANSMISSION SPEED SENSOR......654
POWER TRAIN OIL PRESSURE......655
FLUSHING......660
TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT......660
TRANSMISSION VALVE FAILS......661
MOVING MACHINE......661
STEERING CONTROL......663
STEERING OIL PRESSURE......664
TESTING HYDRAULIC FAN......666
BRAKE SYSTEM......667
MEASURING BRAKE OIL PRESSURE......667
TESTING WEAR OF WHEEL BRAKE DISC......669
BLEEDING AIR FROM BRAKE CIRCUIT......670
TESTING WEAR OF PARKING BRAKE DISC......671
MANUAL RELEASE METHOD FOR PARKING BRAKE......672
ACCUMULATOR CHARGE PRESSURE......673
PPC OIL PRESSURE......675
WORK EQUIPMENT HYDRAULIC PRESSURE......678
BUCKET POSITIONER......680
LIFT ARM KICK-OUT......681
PROXIMITY SWITCH ACTUATION......682
ADJUSTING MACHINE MONITOR......683
LOAD METER......686
BLEEDING AIR......690
RELEASING REMAINING PRESSURE......691
IN HYDRAULIC CIRCUIT......691
E.C.S.S. DAMPER CIRCUIT......692
PM-CLINIC INSPECTION TABLE......693
GENERAL TROUBLESHOOTING......697
POINTS TO REMEMBER WHEN TROUBLESHOOTING......698
SEQUENCE OF EVENTS IN TROUBLESHOOTING......700
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE......701
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT......701
HANDLING ELECTRONIC CONTROL UNIT......706
WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS......707
WHEN HANDLING HYDRAULIC EQUIPMENT......708
CHECKS BEFORE TROUBLESHOOTING......710
EQUIPMENT FOR TROUBLESHOOTING ELECTRICAL SYSTEM......710
SPECIAL FUNCTIONS OF MACHINE MONITOR......712
FLOW OF MODES AND FUNCTIONS......713
FAILURE CODE TABLE......721
MONITORING CODE TABLE......734
USING TROUBLESHOOTING CHARTS......746
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......750
INFORMATION CONTAINED IN TESTING PROCEDURES......770
CONNECTOR TYPES AND LOCATIONS......772
CONNECTOR LAYOUT DRAWING......780
TRANSMISSION CONTROL SYSTEM DIAGRAM......786
ERROR CODE [1500L1]......789
DOUBLE ENGAGEMENT DETECTED......789
ERROR CODE [15SAL1]......790
F_ECMV FILL SWITCH SYSTEM SHORTED......790
ERROR CODE [15SALH]......791
F_ECMV FILL SWITCH SYSTEM OPEN......791
ERROR CODE [15SBL1]......792
R_ECMV FILL SWITCH SYSTEM SHORTED......792
ERROR CODE [15SBLH]......793
R_ECMV FILL SWITCH SYSTEM OPEN......793
ERROR CODE [15SEL1]......794
1ST_ECMV FILL SWITCH SYSTEM SHORTED......794
ERROR CODE [15SELH]......796
1ST_ECMV FILL SWITCH SYSTEM open......796
ERROR CODE [15SFL1]......798
2ND_ECMV FILL SWITCH SYSTEM SHORTED......798
ERROR CODE [15SFLH]......800
2ND_ECMV FILL SWITCH SYSTEM OPEN......800
ERROR CODE [15SGL1]......802
3RD_ECMV FILL SWITCH SYSTEM SHORTED......802
ERROR CODE [15SGLH]......804
3RD_ECMV FILL SWITCH SYSTEM OPEN......804
ERROR CODE [15SHL1]......806
4TH_ECMV FILL SWITCH SYSTEM SHORTED......806
ERROR CODE [15SHLH]......808
4TH_ECMV FILL SWITCH SYSTEM OPEN......808
ERROR CODE [15SJL1]......810
LOCKUP_ECMV FILL SWITCH SYSTEM SHORTED......810
ERROR CODE [15SJLH]......811
LOCKUP_ECMV FILL SWITCH SYSTEM OPEN......811
ERROR CODE [989F00]......812
TRANSMISSION PROTECTION CAUTION......812
ERROR CODE [B@C7NS]......814
REAR BRAKE COOLING OIL OVERHEAT FAULT......814
ERROR CODE [D150KA]......816
EMERGENCY STEERING RELAY SYSTEM OPEN......816
ERROR CODE [D150KB]......817
EMERGENCY STEERING RELAY SYSTEM SHORTED......817
ERROR CODE [D160KA]......818
BACKUP LAMP RELAY SYSTEM OPEN......818
ERROR CODE [D160KB]......819
BACKUP LAMP RELAY SYSTEM SHORTED......819
ERROR CODE [D191KA]......820
NEUTRAL SAFETY RELAY SYSTEM OPEN......820
ERROR CODE [D191KB]......822
NEUTRAL SAFETY RELAY SYSTEM SHORTED......822
ERROR CODE [D192KA]......824
TRAVEL DAMPER RELAY SYSTEM OPEN......824
ERROR CODE [D192KB]......825
TRAVEL DAMPER RELAY SYSTEM SHORTED......825
ERROR CODE [D198KB]......826
LOW TEMPERATURE BYPASS RELAY SYSTEM SHORTED......826
ERROR CODE [D198KY]......828
LOW TEMPERATURE BYPASS RELAY SYSTEM OPEN......828
ERROR CODE [DAQ0KK]......830
CONTROLLER POWER SUPPLY TO MONITOR LOW......830
ERROR CODE [DAQ2KK]......831
DEFECTIVE SOLENOID POWER SUPPLY......831
ERROR CODE [DAQ9KQ]......832
MODEL SELECTION SIGNAL MISMATCH......832
ERROR CODE [DDK3KA]......834
NO JOYSTICK FORWARD/REVERSE SIGNAL......834
ERROR CODE [DDK4KB]......836
MULTIPLE JOYSTICK FORWARD OR/REVERSE SIGNALS......836
ERROR CODE [DDK4KA]......838
NO INPUT FROM JOYSTICK SWITCH......838
ERROR CODE [DDK4KB]......840
NO INPUT FROM JOYSTICK SWITCH......840
ERROR CODE [DDK5LD]......842
SHORT CIRCUIT IN POWER SOURCE FOR JOYSTICK SHIFT UP/SHIFT DOWN SWITCH......842
ERROR CODE [DDK6KA]......844
FORWARD-REVERSE SIGNAL FAULT......844
ERROR CODE [DDK6KB]......846
MULTIPLE FORWARD-REVERSE SIGNAL INPUTS......846
ERROR CODE [DDS5KA]......848
STEERING PRESSURE SWITCH OPEN......848
ERROR CODE [DDS5KB]......850
STEERING PRESSURE SWITCH SHORTED......850
ERROR CODE [DDT0L4]......852
MANUAL/AUTO-SHIFT SELECTOR SELECTION FAILURE......852
ERROR CODE [DDT4LD]......854
GROUND FAULT IN TRANSMISSION CUT-OFF SWITCH......854
ERROR CODE [DDW9LD]......856
SHORT IN KICKDOWN SWITCH SYSTEM......856
ERROR CODE [DDWLLD]......858
GROUND FAULT IN HOLD SWITCH SYSTEM......858
ERROR CODE [DF10KA]......860
NO INPUT SIGNAL IN GEAR SHIFT LEVER......860
ERROR CODE [DF10KB]......862
MULTIPLE GEAR SHIFT LEVER SIGNALS......862
ERROR CODE [DGF1KX]......864
TRANSMISSION OIL TEMPERATURE SENSOR SYSTEM FAILURE......864
ERROR CODE [DGR2KA]......866
REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM OPEN......866
ERROR CODE [DGR2KB]......868
GROUND FAULT IN REAR BRAKE OIL TEMPERATURE SENSOR SYSTEM......868
ERROR CODE [DHT1KX]......869
TRANSMISSION CUT-OFF (LEFT BRAKE PRESSURE SENSOR) SIGNAL OPEN......869
ERROR CODE [DLE2KA]......870
ENGINE SPEED SENSOR OPEN......870
ERROR CODE [DLE2LC]......871
ENGINE SPEED SENSOR SHORTED......871
ERROR CODE [DLT3KA]......872
SPEED SENSOR SYSTEM OPEN......872
ERROR CODE [DT20KB]......873
GROUND FAULT IN INDICATOR LAMP SYSTEM (TRANSMISSION CUT-OFF SWITCH)......873
ERROR CODE [DW7BKA]......874
FAN PUMP REVERSE SOLENOID SYSTEM OPEN......874
ERROR CODE [DW7BKB]......875
FAN REVERSE SOLENOID SYSTEM SHORTED......875
ERROR CODE [DW7CKA]......876
SWITCH PUMP CUT-OFF RELAY OPEN......876
ERROR CODE [DW7CKB]......877
SWITCH PUMP CUT-OFF RELAY GROUND FAULT......877
ERROR CODE [DX16KA]......878
FAN PUMP EPC SOLENOID SYSTEM OPEN......878
ERROR CODE [DX16KB]......879
FAN PUMP EPC SOLENOID SYSTEM GROUND FAULT......879
ERROR CODE [DXH1KA]......880
LOCK-UP CLUTCH_ECMV SOLENOID SYSTEM OPEN......880
ERROR CODE [DXH1KB]......881
LOCK-UP CLUTCH ECMV SOLENOID SYSTEM SHORTED......881
ERROR CODE [DXH4KA]......882
1ST_ECMV SOLENOID SYSTEM OPEN......882
ERROR CODE [DXH4KB]......883
1ST_ECMV SOLENOID SYSTEM SHORTED......883
ERROR CODE [DXH5KA]......884
2ND_ECMV SOLENOID SYSTEM OPEN......884
ERROR CODE [DXH5KB]......885
2ND_ECMV SOLENOID SYSTEM SHORTED......885
ERROR CODE [DXH6KA]......886
3RD_ECMV SOLENOID SYSTEM OPEN......886
ERROR CODE [DXH6KB]......887
3RD_ECMV SOLENOID SYSTEM SHORTED......887
ERROR CODE [DXH7KA]......888
R_ECMV SOLENOID SYSTEM OPEN......888
ERROR CODE [DXH7KB]......889
R_ECMV SOLENOID SYSTEM GROUND FAULT......889
ERROR CODE [DXH8KA]......890
F_ECMV SOLENOID SYSTEM OPEN......890
ERROR CODE [DXH8KB]......891
F_ECMV SOLENOID SYSTEM GROUND FAULT......891
ERROR CODE [DXHHKA]......892
4TH_ECMV SOLENOID SYSTEM OPEN......892
ERROR CODE [DXHHKB]......893
4TH_ECMV SOLENOID SYSTEM SHORTED......893
ERROR CODE [DY30MA]......894
MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE......894
ERROR CODE [DY30MC]......896
MOTOR-DRIVEN EMERGENCY STEERING PUMP FAILURE......896
ACTION CODE [TM-1]......898
OPEN OR SHORT IN KICKDOWN SWITCH SYSTEM......898
ACTION CODE [TM-2]......900
HOLD SWITCH SYSTEM OPEN OR SHORT......900
ACTION CODE [TM-3]......902
TORQUE CONVERTER LOCK-UP SWITCH SYSTEM FAILURE......902
ACTION CODE [TM-4]......904
NEUTRAL SIGNAL SYSTEM FAILURE......904
ACTION CODE [TM-5]......906
EMERGENCY STEERING SWITCH SIGNAL SYSTEM FAILURE......906
ACTION CODE [TM-6]......908
TRANSMISSION CUT-OFF SWITCH SYSTEM OPEN OR SHORTED......908
ACTION CODE [TM-7]......909
TRANSMISSION CUT-OFF SETTING SWITCH SYSTEM OPEN OR SHORTED......909
ACTION CODE [TM-8]......910
TRANSMISSION CUT-OFF (LEFT BRAKE SENSOR) SIGNAL SHORTED......910
ACTION CODE [TM-9]......911
JOYSTICK SHIFT UP/SHIFT DOWN SWITCH SYSTEM FAILURE......911
ACTION CODE [TM-10A]......912
JOYSTICK ON/OFF CHANGE OVER SWITCH SYSTEM FAILURE......912
ACTION CODE [TM-10B]......914
IGNITION SWITCH "C" (IGN C) SIGNAL SYSTEM FAILURE......914
ACTION CODE [TM-11]......916
FNR SWITCH SYSTEM FAILURE......916
ACTION CODE [TM-12]......917
ENGINE POWER MODE SWITCH OPEN OR SHORTED......917
ACTION CODE [TM-13]......918
OPEN OR SHORT IN TRAVEL DAMPER ON/OFF SWITCH......918
ACTION CODE [TM-14]......919
OPEN OR SHORT IN HYDRAULIC FAN REVERSE SIGNAL SYSTEM......919
ACTION CODE [TM-15]......920
SHORT IN MOTOR DRIVEN EMERGENCY STEERING RELAY SYSTEM......920
ACTION CODE [TM-16]......921
SHORT IN TRAVEL DAMPER RELAY SYSTEM......921
ACTION CODE [TM-17]......922
SWITCH PUMP CUT-OFF RELAY SYSTEM SHORTED......922
ACTION CODE [TM-18]......923
BACK LAMP RELAY SYSTEM SHORTED......923
ACTION CODE [TM-19]......924
NEUTRAL SYSTEM SHORTED......924
ACTION CODE [TM-20]......926
F_ECMV SOLENOID SYSTEM SHORTED......926
ACTION CODE [TM-21]......927
R_ECMV SOLENOID SYSTEM SHORTED......927
ACTION CODE [TM-22]......928
1ST_ECMV SOLENOID SYSTEM SHORTED......928
ACTION CODE [TM-23]......929
2ND_ECMV SOLENOID SYSTEM SHORTED......929
ACTION CODE [TM-24]......930
3RD_ECMV SOLENOID SYSTEM SHORTED......930
ACTION CODE [TM-25]......931
4TH_ECMV SOLENOID SYSTEM SHORTED......931
ACTION CODE [TM-26]......932
LOCK-UP ECMV SOLENOID SYSTEM SHORTED......932
ACTION CODE [TM-27]......933
FAN PUMP EPC SOLENOID SYSTEM SHORTED......933
ACTION CODE [TM-28]......934
FAN REVERSE SOLENOID SYSTEM SHORTED......934
ACTION CODE [TM-29]......935
SPEED SENSOR SYSTEM FAILURE......935
INFORMATION CONTAINED IN TESTING PROCEDURES......942
CONNECTOR TYPES AND LOCATIONS......944
CONNECTOR LAYOUT DRAWING......952
WORK EQUIPMENT SYSTEM DIAGRAM......958
ERROR CODE [D193KA]......962
DEFECTIVE JOYSTICK STEERING RELAY SYSTEM......962
ERROR CODE [D193KB]......964
JOYSTICK SOLENOID RELAY OUTPUT SYSTEM SHORTED......964
ERROR CODE [DB90KK]......966
LOWERING WORK EQUIPMENT CONTROLLER POWER SUPPLY FAULT......966
ERROR CODE [DB92KK]......968
DEFECTIVE SOLENOID POWER SUPPLY......968
ERROR CODE [DB95KX]......970
OPEN IN 5 V POWER SUPPLY......970
ERROR CODE [DD1ALD]......972
DEFECTIVE REMOTE UP SWITCH......972
ERROR CODE [DD1BLD]......974
DEFECTIVE REMOTE DOWN SWITCH......974
ERROR CODE [DFAOKM]......976
DEFECTIVE NEUTRAL CAUTION FOR JOYSTICK WORK EQUIPMENT......976
ERROR CODE [DK59KA]......978
DEFECTIVE EPC POTENTIOMETER......978
ERROR CODE [DK59KY]......980
DEFECTIVE EPC POTENTIOMETER......980
ERROR CODE [DK59L8]......982
DEFECTIVE EPC POTENTIOMETER......982
ERROR CODE [DK5AKA]......984
DEFECTIVE EPC POTENTIOMETER......984
ERROR CODE [DK5AKY]......986
DEFECTIVE EPC POTENTIOMETER......986
ERROR CODE [DK5BKA]......988
DEFECTIVE EPC POTENTIOMETER......988
ERROR CODE [DK5BKY]......990
DEFECTIVE EPC POTENTIOMETER......990
ERROR CODE [DK5BL8]......992
DEFECTIVE EPC POTENTIOMETER......992
ERROR CODE [DK5CKA]......994
DEFECTIVE EPC POTENTIOMETER......994
ERROR CODE [DK5CKY]......996
DEFECTIVE EPC POTENTIOMETER......996
ERROR CODE [DK5DKA]......998
DEFECTIVE 3RD VALVE POTENTIOMETER LEVER......998
ERROR CODE [DK5DL8]......1000
DEFECTIVE 3RD EPC POTENTIOMETER......1000
ERROR CODE [DK5EKA]......1002
DEFECTIVE 3RD VALVE POTENTIOMETER LEVER......1002
ERROR CODE [DK5EKY]......1004
DEFECTIVE 3RD VALVE POTENTIOMETER LEVER......1004
ERROR CODE [DK5FKA]......1006
DEFECTIVE JOYSTICK STEERING EPC SYSTEM (MAIN CIRCUIT OPEN OR SHORTED)......1006
ERROR CODE [DK5FKY]......1008
DEFECTIVE JOYSTICK STEERING EPC POTENTIOMETER SYSTEM (MAIN CIRCUIT SHORTED)......1008
ERROR CODE [DK5FKM]......1009
JOYSTICK STEERING EPC LEVER NEUTRAL SYSTEM CAUTION......1009
ERROR CODE [DK5FL8]......1010
DEFECTIVE JOYSTICK STEERING EPC LEVER POTENTIOMETER INPUT SIGNAL......1010
ERROR CODE [DK5GKA]......1012
DEFECTIVE JOYSTICK STEERING EPC POTENTIOMETER SYSTEM (OPEN OR SHORT IN SUB CIRCUIT)......1012
ERROR CODE [DK5GKY]......1014
DEFECTIVE JOYSTICK STEERING EPC POTENTIOMETER SYSTEM (SUB CIRCUIT SHORT)......1014
ERROR CODE [DKAOKA]......1016
DEFECTIVE LIFT ARM ANGLE SENSOR SYSTEM (OPEN OR SHORT)......1016
ERROR CODE [DKAOKY]......1018
DEFECTIVE LIFT ARM ANGLE SENSOR (SYSTEM SHORTED)......1018
ERROR CODE [DLE2LC]......1020
DEFECTIVE ENGINE SPEED SENSOR SYSTEM......1020
ERROR CODE [DLT3LC]......1021
DEFECTIVE TRANSMISSION OUTPUT AXLE SPEED SENSOR SYSTEM (OPEN)......1021
ERROR CODE [DUM1KB]......1022
REMOTE POSITIONER GROUND FAULT......1022
ERROR CODE [DUM2KB]......1023
REMOTE POSITIONER GROUND FAULT......1023
ERROR CODE [DW4PKA]......1024
RAISE EPC SOLENOID FAULT......1024
ERROR CODE [DW4PKB]......1025
RAISE EPC SOLENOID FAULT......1025
ERROR CODE [DW4QKA]......1026
LOWER EPC SOLENOID FAULT......1026
ERROR CODE [DW4QKB]......1027
LOWER EPC SOLENOID FAULT......1027
ERROR CODE [DW4RKA]......1028
TILT EPC SOLENOID FAULT......1028
ERROR CODE [DW4RKB]......1029
TILT EPC SOLENOID FAULT......1029
ERROR CODE [DW4SKA]......1030
DUMP EPC SOLENOID FAULT......1030
ERROR CODE [DW4SKB]......1031
DUMP EPC SOLENOID FAULT......1031
ERROR CODE [DWM1KA]......1032
LOCK EPC SOLENOID FAULT......1032
ERROR CODE [DWM1KB]......1033
LOCK EPC SOLENOID FAULT......1033
ERROR CODE [DWN6KA]......1034
DEFECTIVE RAISE DETENT SYSTEM......1034
ERROR CODE [DWN6KB]......1036
DEFECTIVE RAISE DETENT SYSTEM......1036
ERROR CODE [DWN7KA]......1038
DEFECTIVE FLOAT DETENT SYSTEM......1038
ERROR CODE [DWN7KB]......1040
DEFECTIVE FLOAT DETENT SYSTEM......1040
ERROR CODE [DWN8KA]......1042
DEFECTIVE TILT DETENT SYSTEM......1042
ERROR CODE [DWN8KB]......1044
DEFECTIVE TILT DETENT SYSTEM......1044
ERROR CODE [DXHJKA]......1046
3RD VALVE EPC SOLENOID FAULT......1046
ERROR CODE [DXHJKB]......1047
3RD VALVE EPC SOLENOID FAULT......1047
ERROR CODE [DXHKKA]......1048
3RD VALVE EPC SOLENOID FAULT......1048
ERROR CODE [DXHKKB]......1049
3RD VALVE EPC SOLENOID FAULT......1049
ERROR CODE: [DXHLKA]......1050
OPEN IN JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM......1050
ERROR CODE: [DXHLKB]......1052
JOYSTICK STEERING RIGHT-HAND EPC SOLENOID SYSTEM GROUND FAULT......1052
ERROR CODE: [DXHMKA]......1054
JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM OPEN......1054
ERROR CODE: [DXHMKB]......1056
JOYSTICK STEERING LEFT-HAND EPC SOLENOID SYSTEM GROUND FAULT......1056
[WRK-1]......1058
LIFT ARM LOCK SWITCH FAILURE......1058
[WRK-2]......1060
DEFECTIVE REMOTE POSITIONER RAISE SETTING......1060
[WRK-3]......1062
DEFECTIVE REMOTE POSITIONER LOWER SETTING......1062
[WRK-4]......1064
DEFECTIVE REMOTE POSITIONER RAISE SETTING......1064
[WRK-5]......1066
DEFECTIVE REMOTE POSITIONER LOWER SETTING......1066
[WRK-6]......1068
DEFECTIVE BUCKET PROXIMITY SWITCH......1068
[WRK-7]......1070
DEFECTIVE BUCKET FULL STROKE SWITCH......1070
[WRK-8]......1072
DEFECTIVE SEMI-AUTO DIGGING SYSTEM......1072
[WRK-9]......1074
DEFECTIVE SEMI-AUTO DIGGING SYSTEM......1074
[WRK-10]......1076
DEFECTIVE JOYSTICK ON/OFF SWITCH SYSTEM......1076
[WRK-11]......1078
DEFECTIVE JOYSTICK STEERING HI/LO SYSTEM......1078
[WRK-12]......1080
DEFECTIVE JOYSTICK SOLENOID RELAY SYSTEM......1080
[WRK-13]......1082
DEFECTIVE RAISE DETENT SYSTEM......1082
[WRK-14]......1084
DEFECTIVE FLOAT DETENT SYSTEM......1084
[WRK-15]......1086
DEFECTIVE TILT DETENT SYSTEM......1086
[WRK-16]......1088
LOCK EPC SOLENOID FAULT......1088
[WRK-17]......1089
RAISE EPC SOLENOID FAULT......1089
[WRK-18]......1090
LOWER EPC SOLENOID FAULT......1090
[WRK-19]......1091
TILT EPC SOLENOID FAULT......1091
[WRK-20]......1092
DUMP EPC SOLENOID FAULT......1092
[WRK-21]......1093
3RD VALVE EPC SOLENOID FAULT......1093
[WRK-22]......1094
3RD VALVE EPC SOLENOID FAULT......1094
[WRK-23]......1095
SHORT IN JOYSTICK STEERING RIGHT EPC SOLENOID SYSTEM......1095
[WRK-24]......1096
SHORT IN JOYSTICK STEERING LEFT EPC SOLENOID SYSTEM......1096
[WRK-25]......1097
DEFECTIVE KICK-OUT FUNCTION BUCKET FLOAT......1097
[WRK-26]......1100
DEFECTIVE KICK-OUT FUNCTION LIFT ARM......1100
[WRK-27]......1103
DEFECTIVE BUCKET LEVER FUNCTION......1103
[WRK-28]......1106
DEFECTIVE FLOAT FUNCTION......1106
INFORMATION CONTAINED IN TESTING PROCEDURES......1112
CONNECTOR TYPES AND LOCATIONS......1114
CONNECTOR LAYOUT DRAWING......1122
MONITOR SYSTEM DIAGRAM......1128
ERROR CODE [2F00MA]......1132
PARKING BRAKE FAILURE......1132
ERROR CODE [2G42ZG]......1134
ACCUMULATOR OIL PRESSURE (FRONT CIRCUIT) LOW......1134
ERROR CODE [2G43ZG]......1136
ACCUMULATOR OIL PRESSURE (REAR BRAKE CIRCUIT) LOW......1136
ERROR CODE [AA1ANX]......1138
AIR CLEANER 1 CLOGGED......1138
ERROR CODE [AB00L6]......1140
DEFECTIVE BATTERY CHARGING CIRCUIT......1140
ERROR CODE [AB00MA]......1142
THE BATTERY CHARGING CIRCUIT IS OUT OF ORDER......1142
ERROR CODE [B@BAZG]......1144
ENGINE OIL PRESSURE LOW......1144
ERROR CODE [B@BAZK]......1145
ENGINE OIL LEVEL LOW......1145
ERROR CODE [B@BCNS]......1146
ENGINE COOLANT TEMPERATURE OVERHEATING......1146
ERROR CODE [B@BCZK]......1147
ALARM INDICATING LOW COOLANT LEVEL......1147
ERROR CODE [B@HANS]......1148
HYDRAULIC OIL TEMPERATURE OVERHEATING......1148
ERROR CODE [B@CENS]......1149
TORQUE CONVERTER OIL TEMPERATURE OVERHEATING......1149
ERROR CODE [D182KZ]......1150
THE PREHEATER RELAY COIL IS OPEN OR SHORTED......1150
ERROR CODE [D5ZHL6]......1152
START SWITCH C (IGN "C") INPUT FAILURE......1152
ERROR CODE [DA80L4]......1154
AUTO-GREASE INPUT ABNORMAL......1154
ERROR CODE [DAF3KK]......1156
WHEN THE SW POWER SUPPLY (FOR OPERATION) IS ON, THE NSW POWER SUPPLY (FOR MEMORY) IS OFF......1156
ERROR CODE [DAF5KP]......1158
5-V POWER SUPPLY OUTPUT FAILURE......1158
ERROR CODE [DAF6KP]......1160
24-V POWER SUPPLY OUTPUT FAILURE......1160
ERROR CODE [DAFBKM]......1162
INCORRECT INFORMATION ON MODEL SELECTION......1162
ERROR CODE [DAFSKQ]......1163
INCORRECT INFORMATION ON METER INDICATION SELECTION......1163
ERROR CODE [DAQSKR]......1164
S-NET COMMUNICATION FAILURE BETWEEN MONITOR PANEL AND TRANSMISSION CONTROLLER......1164
ERROR CODE [DBQSKR]......1166
S-NET COMMUNICATION FAILURE BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER......1166
ERROR CODE [DB9SKR]......1168
S-NET COMMUNICATION FAILURE BETWEEN MONITOR PANEL AND WORK EQUIPMENT CONTROLLER......1168
ERROR CODE [DD15LD]......1170
MONITOR PANEL MODE SELECTOR SWITCH 1 [n] (PANEL SW1) INPUT ERROR......1170
ERROR CODE [DD16LD]......1172
MONITOR PANEL MODE SELECTOR SWITCH 1 [‡] (PANEL SW2) INPUT ERROR......1172
ERROR CODE [DD17LD]......1174
MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SW3) INPUT ERROR......1174
ERROR CODE [DD18LD]......1176
MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SW4) INPUT ERROR......1176
ERROR CODE [DD1CLD]......1178
SUB-TOTAL SWITCH FAILURE......1178
ERROR CODE [DDS5L6]......1180
DECREASED STEERING OIL PRESSURE......1180
ERROR CODE [DDY0LD]......1182
CANCEL SWITCH FAILURE......1182
ERROR CODE [DGE2KX]......1184
ENGINE COOLANT TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE......1184
ERROR CODE [DGE3L6]......1186
ABNORMAL CONNECTION OF ENGINE COOLANT TEMPERATURE (LOW TEMPERATURE) SENSOR SYSTEM......1186
ERROR CODE [DGH2KX]......1188
HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM FAILURE......1188
ERROR CODE [DGT1KX]......1189
TORQUE CONVERTER OIL TEMPERATURE SENSOR SYSTEM FAILURE......1189
ERROR CODE [DHE4L6]......1190
ENGINE OIL PRESSURE SENSOR SYSTEM FAILURE......1190
ERROR CODE [DHPCKX]......1192
BOTTOM PRESSURE SENSOR FAILURE......1192
ERROR CODE [DHPDKX]......1194
HEAD PRESSURE SENSOR FAILURE......1194
ERROR CODE [DKA0KX]......1196
LIFT ARM ANGLE SENSOR FAILURE......1196
ERROR CODE [DV00KB]......1198
SHORTED ALARM BUZZER OUTPUT SYSTEM......1198
ERROR CODE [DY30ME]......1200
EMERGENCY STEERING REMAINS ACTUATED FOR MORE THAN ONE MINUTE......1200
ACTION CODE [MON-1]......1202
PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT UP WHEN THE PARKING BRAKE SWITCH IS TURNED ON......1202
ACTION CODE [MON-2]......1204
CIRCUIT DIAGNOSTIC PROCEDURES FOR ERROR CODE......1204
ACTION CODE [MON-3]......1206
BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP WHEN THE EMERGENCY BRAKE IS APPLIED (REAR CIRCUIT)......1206
ACTION CODE [MON-4]......1208
AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT......1208
ACTION CODE [MON-5]......1210
ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT......1210
ACTION CODE [MON-6]......1211
ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT......1211
ACTION CODE [MON-7]......1212
ENGINE COOLANT TEMPERATURE CAUTION LAMP DOES NOT LIGHT......1212
ACTION CODE [MON-8]......1214
COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT......1214
ACTION CODE [MON-9]......1215
HYDRAULIC OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT......1215
ACTION CODE [MON-10]......1216
TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT......1216
ACTION CODE [MON-11]......1218
STEERING HYDRAULIC CAUTION LAMP DOES NOT LIGHT......1218
ACTION CODE [MON-12]......1220
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW1)......1220
ACTION CODE [MON-13]......1222
INPUT FAULT IN MONITOR PANEL MODE SWITCH 1 (PANEL SW2)......1222
ACTION CODE [MON-14]......1224
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW3)......1224
ACTION CODE [MON-15]......1226
INPUT FAULT IN MONITOR PANEL MODE SWITCH 2 (PANEL SW4)......1226
ACTION CODE [MON-16]......1228
DEFECTIVE SUBTOTAL SWITCH......1228
ACTION CODE [MON-17]......1230
DEFECTIVE CANCEL SWITCH......1230
ACTION CODE [MON-18]......1232
DEFECTIVE BOTTOM PRESSURE SENSOR (SHORT FAULT)......1232
ACTION CODE [MON-19]......1234
DEFECTIVE HEAD SENSOR......1234
ACTION CODE [MON-20]......1236
ALARM BUZZER DOES NOT SOUND OR STOP......1236
30 DISASSEMBLY AND ASSEMBLY......1239
METHOD OF USING MANUAL......1242
PRECAUTIONS WHEN PERFORMING SERVICE OPERATIONS......1243
SPECIAL TOOL LIST......1246
SKETCH OF SPECIAL TOOLS......1249
CONNECTOR REPAIR PROCEDURES......1263
STRIPPING INSULATION......1263
WIRE INSPECTION......1263
CONTACT TERMINAL REMOVAL (HD30 TYPE)......1264
CRIMPING CONTACT TERMINAL (HD30 TYPE)......1265
INSERTION OF CONTACT TERMINAL (HD30 TYPE)......1266
CONTACT TERMINAL REMOVAL (DT TYPE)......1267
CRIMPING CONTACT TERMINAL (DT TYPE)......1268
INSERTION OF CONTACT TERMINAL (DT TYPE)......1269
ENGINE......1270
ALTERNATOR......1270
CYLINDER HEAD......1270
DAMPER......1270
ENGINE OIL COOLER......1270
ENGINE FRONT SEAL......1270
ENGINE REAR SEAL......1270
FUEL INJECTION PUMP FOR LEFT BANK......1270
FUEL INJECTION PUMP FOR RIGHT BANK......1270
NOZZLE HOLDER......1270
STARTING MOTOR......1270
TURBOCHARGER......1270
WATER PUMP......1270
REMOVAL......1271
INSTALLATION......1275
RADIATOR FAN MOTOR......1276
REMOVAL......1276
INSTALLATION......1277
AFTERCOOLER......1278
REMOVAL......1278
INSTALLATION......1278
FAN AND FAN MOTOR......1279
REMOVAL......1279
INSTALLATION......1280
FUEL TANK......1281
REMOVAL......1281
INSTALLATION......1283
PARKING BRAKE DISC PLATE......1284
REMOVAL......1284
INSTALLATION......1286
TORQUE CONVERTER AND TRANSMISSION......1288
REMOVAL......1288
INSTALLATION......1292
BLEEDING THE HYDRAULIC BRAKE CIRCUIT......1293
TRANSMISSION......1294
DISASSEMBLY......1294
ASSEMBLY......1302
TRANSMISSION CLUTCH PACK......1311
DISASSEMBLY......1311
FORWARD AND REVERSE CLUTCH PACKS......1311
1ST AND 4TH CLUTCH PACK......1313
2ND AND 3RD CLUTCH PACK......1316
ASSEMBLY......1319
FORWARD AND REVERSE CLUTCH PACKS......1319
1ST AND 4TH CLUTCH PACK......1322
2ND AND 3RD CLUTCH PACK......1326
PARKING BRAKE......1331
DISASSEMBLY......1331
ASSEMBLY......1334
TORQUE CONVERTER (STANDARD)......1339
DISASSEMBLY......1339
ASSEMBLY......1341
TORQUE CONVERTER (LOCK-UP)......1344
DISASSEMBLY......1344
ASSEMBLY......1347
REAR AXLE......1351
REMOVAL......1351
INSTALLATION......1353
FRONT AXLE......1355
REMOVAL......1355
INSTALLATION......1356
AXLE HOUSING......1357
DISASSEMBLY......1357
ASSEMBLY......1362
DIFFERENTIAL......1368
DISASSEMBLY......1368
ASSEMBLY......1374
CENTER HINGE PIN......1385
REMOVAL......1385
INSTALLATION......1390
CAB......1395
REMOVAL......1395
INSTALLATION......1397
CAB AND FLOOR FRAME......1398
REMOVAL......1398
INSTALLATION......1401
TRANSMISSION, WORK EQUIPMENT, PPC PUMP......1402
REMOVAL......1402
INSTALLATION......1402
STEERING, SWITCHING, AND FAN PUMP......1403
REMOVAL......1403
INSTALLATION......1403
STEERING DEMAND VALVE......1404
REMOVAL......1404
INSTALLATION......1405
DISASSEMBLY......1406
ASSEMBLY......1410
ORBITROL VALVE......1414
REMOVAL......1414
INSTALLATION......1415
DISASSEMBLY......1416
ASSEMBLY......1419
CONTROL SIDE......1419
ECSS VALVE......1424
REMOVAL......1424
INSTALLATION......1424
WORK EQUIPMENT VALVE......1425
REMOVAL......1425
INSTALLATION......1427
HYDRAULIC CYLINDERS......1428
STEERING, LIFT, AND BUCKET......1428
DISASSEMBLY......1429
ASSEMBLY......1432
HYDRAULIC TANK......1438
REMOVAL......1438
INSTALLATION......1439
WORK EQUIPMENT......1440
REMOVAL......1440
INSTALLATION......1443
COUNTERWEIGHT......1445
REMOVAL......1445
INSTALLATION......1445
AIR CONDITIONER......1446
REMOVAL......1446
INSTALLATION......1449
AIR CONDITIONER COMPRESSOR......1450
REMOVAL......1450
INSTALLATION......1450
OPERATOR’S SEAT......1451
DISASSEMBLY......1451
ASSEMBLY......1459
90 OTHERS......1465
POWER TRAIN OIL CIRCUIT DIAGRAM......1466
WITHOUT TORQUE CONVERTER LOCKUP CLUTCH......1466
WITH TORQUE CONVERTER LOCKUP CLUTCH......1467
BRAKE OIL CIRCUIT DIAGRAM......1468
HYDRAULIC CIRCUIT SCHEMATIC......1470
ELECTRICAL SCHEMATIC......1472
STANDARD......1472
FLOOR HARNESS - CAB......1472
FLOOR HARNESS - TRANSMISSION CONTROLLER......1474
FLOOR HARNESS - TRANSMISSION HARNESS......1476
FLOOR HARNESS - REAR HARNESS......1478
FLOOR HARNESS - RELAY UNITS......1480
WITH JOYSTICK STEERING......1482
FLOOR HARNESS - CAB......1482
FLOOR HARNESS - TRANSMISSION CONTROLLER......1484
FLOOR HARNESS - JOYSTICK HARNESS......1486
FLOOR HARNESS - TRANSMISSION HARNESS......1488
FLOOR HARNESS - REAR HARNESS......1490
FLOOR HARNESS - RELAY UNITS......1492
ENGINE HARNESS......1494
REAR HARNESS......1496
FRONT FRAME HARNESS......1498
CAB HARNESS......1500
MONITOR PANEL CONTROLLER......1502
A/C RELAY HARNESS......1504
TRANSMISSION HARNESS......1506
JOYSTICK CONTROLLER HARNESS......1508
KOMTRAX HARNESS......1510
Komatsu WA400L-Series Wheel Loaders Repair Service Manual
