Part of the Case Repair Manuals.
This is TM 5-3805-292-23, the U.S. Army field maintenance technical manual dated January 2010. It covers the M400T tracked and M400W wheeled skid steer loaders. The engine is the Iveco F5C 3.2 L turbo diesel, rated 69 hp (51 kW) net. The book also covers the hydrostatic drive, loader hydraulics, cab, ROPS and the 24 volt electrical system.
A guessed relief setting or a borrowed torque value is how a pump gets cooked or a bolt lets go. This book gives the real checkout numbers: main relief at 3,000 ± 50 psi, a 362 psi minimum charge pressure at full throttle, and intake and exhaust valve lash.
You also get troubleshooting charts, PMCS tables, chain case and track work, attachments and the electrical schematics.
What's Inside This Case M400T, M400W Manual
| System | Pages | Key Topics |
|---|---|---|
| Front Matter and Table of Contents | 1-46 | Warning Summary, How to Use This Manual, Table of Contents |
| General Information, Equipment Data, Theory of Operation | 47-78 | Scope, Equipment Characteristics, Equipment Data for M400T and M400W, Theory of Operation |
| Troubleshooting | 79-158 | Troubleshooting Symptom Index, Engine, Hydraulic, Powertrain and Electrical Troubleshooting Procedures |
| Operational Checkout | 159-194 | Engine, Hydrostatic System and Hydraulic System Checks: Fuel, Oil, Charge, Anti-Stall, Circuit Relief and Main Relief Pressures |
| Preventive Maintenance Checks and Services (PMCS) | 195-220 | PMCS Introduction and PMCS Table |
| Service Upon Receipt, Engine Accessories | 221-280 | Service Upon Receipt, Alternator, A/C Compressor, Coolant Recovery Bottle, Engine Mounts, Fan and Shroud, Inline Fuel Filter, Fuel Lines, Muffler, Radiator Hoses, Starter |
| Engine Assembly and Lubrication | 281-408 | Engine Assembly, Block Plugs, Dipstick and Oil Fill Neck, Clutch, Engine Oil Service, Crankshaft Pulley, Breather, Oil Cooler, Oil Filter, Oil Pan, Oil Pump, Exhaust Manifold, Flywheel, Front Cover |
| Fuel System and Engine Top End | 409-472 | Fuel Filter Head and Element, Injection Lines, Injectors, Fuel Injection Pump, Intake Manifold, Rear Seal, Thermostat, Turbocharger, Valve Covers, Water Pump, Belts |
| Cylinder Head, Valves, Air and Cooling | 473-536 | Cylinder Head Assembly, Fan Support, Rocker Unit, Valve Lash Adjustment, Finding Top Dead Center, Air Cleaner, Radiator and Cooler Module, Cooling System Service |
| Powertrain, M400W | 537-610 | Chain Replacement, Chain Tank Service, Powertrain Lines, Sprockets, Return Oil Manifold, Hydraulic Drive Motors, Tandem Pump, Axle, Brake Pilot Valve, Hydraulic Oil Filter |
| Tracks and Wheels, M400T Powertrain | 611-664 | Track Maintenance, Wheel and Tire Assembly, Track Replacement, Hydraulic Drive Motor and Oil Service, Tandem Pump, Track Frame Assembly |
| Loader Hydraulics | 665-742 | Auxiliary Hydraulic Cable and Pedal, Boom Override Valve, Hydraulic Hoses, Joystick Valve, Lift and Tilt Cylinders, Gear Pump, Main Hydraulic Valve, Raising Loader Arms with Engine Stopped |
| Air Conditioning, Consoles and Chassis Covers | 743-806 | A/C Condenser, Receiver/Dryer, A/C System Maintenance, Consoles, Chassis Covers, Counterweight, Data Plates, Heater Hoses |
| Cab, ROPS and Loader Arm | 807-1002 | Joystick Consoles, Loader Arm, Rear Window, Refrigerant Hoses, ROPS, Seat Belt, Mirrors, Windows, Coupler, Doors, Seat, Throttle Controls |
| Heater, Hood and ROPS Tilting | 1003-1056 | Washer Reservoir, Deluxe Heater and a/C, Engine Compartment Hood, Exhaust Extension, Headliner Duct, ROPS Tilting Operation |
| Electrical: Switches, Batteries and Harnesses | 1057-1162 | A/C and Restriction Switches, Sensors, Backup Alarm, Batteries, Battery Disconnect and Cables, Cab, Chassis, Door and Engine Wiring Harnesses |
| Electrical: Panel, Power and Lighting | 1163-1236 | Fuel Level Sender, Injection Pump Harness, Horn, HVAC Harnesses, Instrument Panel, NATO Slave Receptacle, Power Equalizer, Power Distribution, Relays, Lights |
| Attachments | 1237-1278 | Auger, Attachment Container, Hammer, Pallet Forks and Bucket Repair |
| General Maintenance Instructions and Torque Limits | 1279-1320 | Mechanical and Electrical General Maintenance, Relieving Hydraulic System Pressure, Splicing, Torque Limits |
| Schematics | 1321-1340 | Electrical Schematic Frames: Engine, Starting and Charging System, Power Center, Harnesses and Consoles |
| Supporting Information | 1341-1384 | References, Maintenance Allocation Chart, Expendable and Durable Items List, Index |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine | Iveco F5C, turbo diesel, Tier 3 Certified | p. 64 |
| Displacement | 195 cu. in. (3.2 L) | p. 64 |
| Gross bare engine power (SAE J1349) | 74 hp (55 kW) | p. 64 |
| Net engine power (SAE J1349) | 69 hp (51 kW) | p. 64 |
| Peak torque @ 1,400 rpm | 203 lb-ft (275 Nm) | p. 64 |
| Travel speed, M400T | 0 to 6.0 mph (0 to 9.6 kph) | p. 64 |
| Travel speed, M400W | 0 to 7.1 mph (0 to 11.4 kph) | p. 64 |
| Auxiliary hydraulic circuit flow | 23.8 gpm (90.1 L/M) | p. 64 |
| Weight, M400T / M400W | 9,100 lb (4,128 kg) / 8,400 lb (3,810 kg) | p. 64 |
| Lifting capacity, M400T / M400W | 2,100 lb (953 kg) / 1,980 lb (898 kg) | p. 64 |
| Tire pressure, M400W only | 40 to 50 PSI (276 to 345 kPa) | p. 64 |
| Engine crankcase oil | 9.0 qt (8.5 L) | p. 65 |
| Hydraulic system capacity / reservoir | 13.2 gal. (50.0 L) / 7.1 gal. (26.9 L) | p. 65 |
| Fuel tank | 23.3 gal. (88.2 L) | p. 65 |
| Main relief pressure | 3,000 ± 50 psi (207 ± 3.5 bar) | p. 186 |
| Charge pressure, minimum at full throttle | 362 psi (25 bar) | p. 171 |
| Valve lash, intake / exhaust | .01 ± .002 in. (0.25 ± 0.05 mm) / .02 ± .002 in. (0.50 ± 0.05 mm) | p. 504 |
| Wheel nut torque, M400W | 100 to 120 lb-ft (135 to 163 Nm) | p. 623 |
| Allowable track sag, M400T | 1/2 to 3/4 in. | p. 632 |
Case M400T, M400W Common Problems This Manual Covers
Engine does not crank
Check the ignition switch and starter solenoid fuses first. Make sure the battery terminals and the single point power distribution block are clean and tight. Check battery charge and load test the batteries. Then check the main fuse and the battery cables. Follow the engine troubleshooting chart step by step and don't skip ahead.
Manual Section: Engine troubleshooting - Engine does not crank p. 86Engine overheats
Check the coolant level and pressure test the cooling system for leaks. Inspect the radiator fins for dirt or damage and clean them. Look for collapsed hoses, then check the air filter and serpentine belt tension. Next, replace the thermostat and flush the system, then check the water pump. Air bubbles in the coolant with the engine running point to the cylinder head or block.
Manual Section: Engine troubleshooting - Engine overheats p. 97Incorrect or no loader function
First make sure the parking brake releases. Then work through the loader valve interlock circuit: check for power at the instrument panel, then the door switch, then the interlock solenoid on the brake pilot valve. Replace the failed switch, panel or harness as the troubleshooting chart directs.
Manual Section: Hydraulic troubleshooting - Incorrect or no loader function p. 104Machine does not have movement
Start the engine, release the parking brake, and confirm the parking brake indicator goes out. Then put a gauge on charge pressure. It must read at least 362 psi (25 bar) at full throttle. If the machine still won't move, check power to the brake release and tandem pump neutral override solenoid and the related circuits.
Manual Section: Powertrain troubleshooting - Machine does not have movement p. 109Frequently Asked Questions
How do I change the engine oil and filter on the M400T or M400W, and how much oil does it take?
Park on level ground and set a 3 gal. container under the engine. Pull the drain plug and O-ring from the oil pan, let it drain, and throw away the O-ring. Remove the right side access panel and turn the filter counterclockwise to remove it. Fill the new filter with clean oil and lube its seal. Tighten it until the seal touches, then a further 3/4 to 1 full turn. Install a new O-ring and the drain plug. Slowly add 9.0 qt (8.5 L) through the oil fill neck and check the level on the dipstick. p. 323
How do I adjust the valve lash on the M400T and M400W engine?
Pull the valve covers and bring cylinder no. 1 to top dead center on its compression stroke. Hold the adjusting stud, loosen the nut, and measure the gap between the rocker arm and the valve cap with a feeler gauge. Intake is .01 ± .002 in. (0.25 ± 0.05 mm). Exhaust is .02 ± .002 in. (0.50 ± 0.05 mm). Only adjust a valve that is out of limits. Then tighten the nut to 15 ± 1 lb-ft (20 ± 2 Nm). Rotate the crankshaft 360 degrees to do the remaining cylinders. Firing order is 1-3-4-2. p. 504
How do I relieve hydraulic system pressure before disconnecting lines?
Park on level ground, lower the work tool to the ground, set the parking brake and stop the engine. Press the power button ON but do not start the engine. Pull the hydraulic boom override. Then move the loader control joystick and the auxiliary hydraulic control pedal through every position. Last, loosen the hydraulic tank filler cap slowly and let any pressure escape before you crack a fitting. p. 1281
How do I check and adjust track tension on the M400T?
Allowable track sag is 1/2 to 3/4 in. Measure it from the top of the lower track run to the bottom of the center roller. To tighten, make sure the fitting is tight and slowly add grease. To loosen, slowly loosen the fitting and let grease escape from the adjuster. That grease is under high pressure, so take it slow. A track that is too tight or too loose wears out faster. p. 632
How do I drain and refill the chain tanks on the M400W?
Set drain containers under the machine. Remove the two drain plugs at the bottom of the left and right chain tanks, drain the oil, and reinstall the plugs. Remove the two fill plugs and fill each side to the bottom of the fill hole. Install the fill plugs. The equipment data lists the chain compartments at 8.0 qt (7.6 L) per side. p. 543
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