HM 400 2 Shop Manual Complete

SEN00239-09
ARTICULATED HM400 -2
DUMP TRUCK
SERIAL NUMBERS 2001 and up
SEN00512-09
ARTICULATED DUMP TRUCK 1SHOP MANUAL
HM400-2
Machine model Serial number

HM400-2 2001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
HM400-2 1
SEN00512-09 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00239-09
00 Index and foreword SEN00511-09

Index SEN00512-09 q
Foreword and general information SEN00513-04
01 Specification SEN00514-01
Specification and technical data SEN00515-01
10 Structure, function and maintenance standard SEN00516-04

Engine and cooling system SEN00517-01
Power train, Part 1 SEN00518-01
Steering system SEN00520-01
Brake system SEN00521-02 q
Undercarriage and frame SEN00522-02 q
Hydraulic system SEN00523-02 q
Cab and its attachments SEN00524-01
Electrical system, Part 1 SEN00525-01
Electrical system, Part 2 SEN00526-02 q
20 Standard value table SEN00528-02

Standard service value table SEN00915-02
30 Testing and adjusting SEN00529-04

Testing and adjusting, Part 1 SEN00916-03 q
40 Troubleshooting SEN00530-03
General information on troubleshooting SEN01107-02 q
Troubleshooting by failure code, General SEN01262-00
Troubleshooting by failure code, Part 1 SEN01108-00
Troubleshooting by failure code, Part 2 SEN01109-02 q
2 HM400-2

Troubleshooting for electrical system (E-mode) SEN01116-01 q
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01117-00
Troubleshooting of engine (S-mode) SEN01118-01 q
50 Disassembly and assembly SEN00531-03

General information on disassembly and assembly SEN01442-03 q
Engine and cooling system SEN01443-03 q
Power train, Part 1 SEN01444-03 q
Power train, Part 2 SEN01445-02 q
Undercarriage and frame SEN01447-02 q
Hydraulic system SEN01448-02
Cab and its attachments SEN01449-02 q
Electrical system SEN01450-02 q
90 Diagrams and drawings SEN00532-04

Hydraulic diagrams and drawings SEN00533-02 q
Electrical diagrams and drawings SEN00534-04 q
HM400-2 3
Table of contents 1
00 Index and foreword
Index SEN00512-09
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN00513-04

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN00515-01
Specification drawings................................................................................................................. 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 6
Fuel, coolant and lubricants ........................................................................................................ 7
10 Structure, function and maintenance standard

Radiator, oil cooler, aftercooler .................................................................................................... 2
Output shaft................................................................................................................................. 3
Power train skeleton.................................................................................................................... 2
Torque converter and transmission hydraulic piping ................................................................... 6
Brake cooling oil control valve (BCV) .......................................................................................... 8
Power train pump ........................................................................................................................ 9
Torque converter ......................................................................................................................... 12
Transmission ............................................................................................................................... 18
Transmission control valve .......................................................................................................... 46
ECMV .......................................................................................................................................... 47
Main relief, torque converter relief valve ..................................................................................... 54
Drive shaft ................................................................................................................................... 2
Axle ............................................................................................................................................. 6
Differential ................................................................................................................................... 10
Limited slip differential................................................................................................................. 22
Final drive.................................................................................................................................... 26
Steering system SEN00520-01
Steering column........................................................................................................................... 2
Brake system SEN00521-02
Brake piping ................................................................................................................................ 2
Brake valve.................................................................................................................................. 4
Accumulator charge valve ........................................................................................................... 7
Accumulator ................................................................................................................................ 11
Slack adjuster.............................................................................................................................. 12
Brake ........................................................................................................................................... 14
4 HM400-2
Proportional reducing valve......................................................................................................... 19

Brake system tank....................................................................................................................... 20
Parking brake .............................................................................................................................. 22
Parking brake solenoid valve ...................................................................................................... 26
Undercarriage and frame SEN00522-02
Suspension ................................................................................................................................. 2
Suspension cylinder .................................................................................................................... 7
Oscillation hitch ........................................................................................................................... 9
Steering, hoist oil pressure piping diagram ................................................................................. 2
Dump body control ...................................................................................................................... 3
Hydraulic tank and filter............................................................................................................... 4
Flow amp valve ........................................................................................................................... 5
Steering valve.............................................................................................................................. 8
Steering cylinder.......................................................................................................................... 12
Hoist valve................................................................................................................................... 14
Dump control valve (EPC valve) ................................................................................................. 20
Pilot check valve ......................................................................................................................... 24
Hoist cylinder............................................................................................................................... 25
Hydraulic pump ........................................................................................................................... 26
ROPS cab ................................................................................................................................... 2
Cab tilt ......................................................................................................................................... 3
Air conditioner ............................................................................................................................. 4
Rear view monitor ....................................................................................................................... 12
Controller related......................................................................................................................... 15
Machine monitor system ............................................................................................................. 2
Automatic shift control system .................................................................................................... 2
Transmission controller ............................................................................................................... 5
Retarder control system .............................................................................................................. 34
Auto emergency steering system................................................................................................ 46
Battery disconnector switch ........................................................................................................ 48
Dump control lever ...................................................................................................................... 50
Playload meter (Card type) ......................................................................................................... 2
Sensors, switches ....................................................................................................................... 2
KOMTRAX terminal system (if equipped) ................................................................................... 12
20 Standard value table

Standard service value table SEN00915-02
Standard value table for engine .................................................................................................. 2
Standard value table for chassis ................................................................................................. 3
30 Testing and adjusting

Testing and adjusting, Part 1 SEN00916-03
Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed............................................................................................................. 7
Testing intake air pressure (boost pressure) ............................................................................... 8
Testing exhaust temperature....................................................................................................... 9
Testing exhaust gas color............................................................................................................ 10
Adjusting valve clearance ........................................................................................................... 11
Testing compression pressure .................................................................................................... 12
HM400-2 5
Testing blow-by pressure............................................................................................................. 14

Testing engine oil pressure.......................................................................................................... 15
Testing EGR valve and bypass valve drive oil pressure.............................................................. 16
Handling of fuel system devices.................................................................................................. 17
Releasing residual pressure from fuel system ............................................................................ 17
Testing fuel pressure ................................................................................................................... 18
Testing fuel return and leakage amount ...................................................................................... 19
Bleeding air from fuel circuit ........................................................................................................ 22
Testing the fuel circuit for leakage ............................................................................................... 24
Testing and adjusting fan belt tension ......................................................................................... 25
Testing and adjusting alternator belt tension ............................................................................... 26
Testing and adjusting air conditioner compressor belt tension.................................................... 27
Testing torque converter stall speed............................................................................................ 3
Testing power train oil pressure................................................................................................... 4
Testing and adjusting of differential lock oil pressure (differential lock spec.) ............................. 12
Adjusting transmission speed sensor.......................................................................................... 17
Testing and adjusting brake oil pressure ..................................................................................... 19
Testing of accumulator nitrogen gas pressure and procedure
for charging accumulator with nitrogen gas ............................................................................. 23
Testing brake performance.......................................................................................................... 27
Bleeding air from brake circuit..................................................................................................... 28
Testing wear of wheel brake disc ................................................................................................ 29
Testing the parking brake pad wear ............................................................................................ 30
Emergency release of the parking brake..................................................................................... 31
Testing and adjusting steering circuit oil pressure....................................................................... 32
Testing and adjusting suspension cylinder .................................................................................. 34
Method of tilting cab up ............................................................................................................... 38
Testing and adjusting dump circuit oil pressure........................................................................... 40
Adjusting body positioner sensor ................................................................................................ 42
Adjusting length of spring in body heating spherical joint............................................................ 44
Handling of voltage circuit of engine controller............................................................................ 44
Adjusting transmission controller................................................................................................. 44
Method for emergency escape at electrical system failure ......................................................... 45
Setting and adjusting various equipments................................................................................... 2
Special function of machine monitor............................................................................................ 11
How to start operation of KOMTRAX terminal............................................................................. 56
Lamp display of KOMTRAX terminal........................................................................................... 61
Pm Clinic check sheet ................................................................................................................. 64
Initial setting of payload meter..................................................................................................... 67
40 Troubleshooting
General information on troubleshooting SEN01107-02
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Connection table for connector pin numbers............................................................................... 8
T-branch box and T-branch adapter table ................................................................................... 44
Troubleshooting by failure code, General SEN01262-00
Troubleshooting by failure code, General.................................................................................... 2
Failure codes table .................................................................................................................. 2
Before troubleshooting by failure code .................................................................................... 10
Information in troubleshooting table......................................................................................... 18
6 HM400-2

Troubleshooting by failure code, Part 1....................................................................................... 3
Failure code [1500L0] Double engagement ............................................................................ 3
Failure code [15B0NX] Transmission oil filter: Clogged .......................................................... 4
Failure code [15F0KM] R o F shifting abuse 1 ....................................................................... 6
Failure code [15F0MB] R o F shifting abuse 2 ....................................................................... 6
Failure code [15F7KM] Transmission forward clutch abuse ................................................... 7
Failure code [15G0MW] Trouble in reverse clutch system (Slip)............................................. 8
Failure code [15G7KM] Transmission reverse clutch abuse ................................................... 10
Failure code [15H0MW] Trouble in Hi clutch system (Slip) ..................................................... 12
Failure code [15J0MW] Trouble in Lo clutch system (Slip) ..................................................... 14
Failure code [15K0MW] Trouble in 1st clutch system (Slip) .................................................... 16
Failure code [15L0MW] Trouble in 2nd clutch system (Slip) ................................................... 18
Failure code [15M0MW] Trouble in 3rd clutch system (Slip) ................................................... 20
Failure code [15SBL1] Trouble in reverse clutch pressure control valve .............................. 22
Failure code [15SBMA] Trouble in reverse clutch pressure control valve ........................... 26
Failure code [15SCL1] Trouble in Hi clutch pressure control valve ...................................... 28
Failure code [15SCMA] Trouble in Hi clutch pressure control valve ................................... 32
Failure code [15SDL1] Trouble in Lo clutch pressure control valve ..................................... 34
Failure code [15SDMA] Trouble in Lo clutch pressure control valve ................................... 36
Failure code [15SEL1] Trouble in 1st clutch pressure control valve ......................................... 3
Failure code [15SEMA] Trouble in 1st clutch pressure control valve ...................................... 6
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve ........................................ 8
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve ..................................... 12
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve ........................................ 14
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve ..................................... 18
Failure code [15SJMA] Trouble in lockup clutch pressure control valve ................................. 20
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve .... 22
Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 ............. 24
Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1............. 26
Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 .............. 28
Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1.............. 30
Failure code [2C4MNX] Clogging of retarder cooling oil filter ..................................................... 32
Failure code [2F00KM] Dragging of parking brake ..................................................................... 34
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) ......................................... 36
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) .......................................... 36
Failure code [989A00] Operation of engine overrun prevention system ..................................... 37
Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) ................ 37
Failure code [A570NX] Clogging of engine oil filter..................................................................... 38
Failure code [AA10NX] Clogging of air cleaner........................................................................... 40
Failure code [AB00MA] Trouble in battery charge circuit ............................................................ 42
Failure code [B@BAZG] Lowering of engine oil pressure........................................................... 43
Failure code [B@BAZK] Lowering of engine oil level.................................................................. 44
Failure code [B@BCNS] Overheating of engine ......................................................................... 45
Failure code [B@BCZK] Lowering of coolant level ..................................................................... 46
Failure code [B@BFZK] Lowering of fuel level ........................................................................... 48
Failure code [B@C6NS] Overheating of brake cooling oil (front)................................................ 49
Failure code [B@C7NS] Overheating of brake cooling oil (rear) ................................................ 49
Failure code [B@C8NS] Overheating of brake cooling oil (center)............................................. 50
Failure code [B@CENS] Overheating of torque converter oil ..................................................... 50
Failure code [B@JANS] Overheating of steering oil ................................................................... 51
Failure code [CA111] Trouble in engine controller ...................................................................... 4
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors........................................ 6
Failure code [CA122] Abnormally high charge pressure............................................................. 8
Failure code [CA123] Abnormally low charge pressure .............................................................. 10
HM400-2 7
Failure code [CA131] Abnormally high throttle sensor signal...................................................... 12

Failure code [CA132] Abnormally low throttle sensor signal ....................................................... 14
Failure code [CA135] Abnormally high engine oil pressure ........................................................ 16
Failure code [CA141] Abnormally low engine oil pressure.......................................................... 18
Failure code [CA144] Abnormally high coolant temperature....................................................... 20
Failure code [CA145] Abnormally low coolant temperature ........................................................ 22
Failure code [CA153] Abnormally high charge temperature ....................................................... 24
Failure code [CA154] Abnormally low charge temperature......................................................... 26
Failure code [CA187] Abnormally low voltage in sensor power supply 2.................................... 27
Failure code [CA221] Abnormally high ambient pressure ........................................................... 28
Failure code [CA222] Abnormally low ambient pressure ............................................................ 30
Failure code [CA227] Abnormally high voltage in sensor power supply 2 .................................. 32
Failure code [CA234] Engine overspeed..................................................................................... 34
Failure code [CA238] Trouble in Ne speed sensor power supply ............................................... 36
Failure code [CA263] Abnormally high fuel temperature............................................................. 38
Failure code [CA265] Abnormally low fuel temperature .............................................................. 40
Failure code [CA271] Short circuit in PCV1 ................................................................................ 41
Failure code [CA272] Disconnection in PCV1............................................................................. 42
Failure code [CA273] Short circuit in PCV2 ................................................................................ 43
Failure code [CA274] Disconnection in PCV2............................................................................. 44
Failure code [CA322] Disconnection or short circuit in injector #1 (L #1).................................... 46
Failure code [CA342] Matching error in engine controller data ................................................... 58
Failure code [CA351] Trouble in injector drive circuit .................................................................. 60
Failure code [CA352] Abnormally low voltage in sensor power supply 1.................................... 62
Failure code [CA386] Abnormally high voltage in sensor power supply 1 .................................. 64
Failure code [CA431] Trouble in idle validation switch ................................................................ 4
Failure code [CA432] Trouble in idle validation process ............................................................. 7
Failure code [CA441] Abnormally low voltage in power supply................................................... 7
Failure code [CA442] Abnormally high voltage in power supply ................................................. 8
Failure code [CA449] Abnormally high common rail pressure 2 ................................................. 8
Failure code [CA451] Abnormally high common rail pressure .................................................... 10
Failure code [CA452] Abnormally low common rail pressure...................................................... 12
Failure code [CA553] Abnormally high common rail pressure 1 ................................................. 12
Failure code [CA554] In-range error in common rail pressure sensor ........................................ 13
Failure code [CA559] Supply pump low pressure 1 .................................................................... 15
Failure code [CA689] Trouble in engine Ne speed sensor.......................................................... 18
Failure code [CA731] Phase error in engine Bkup speed sensor ............................................... 20
Failure code [CA757] Loss of all data in engine controller .......................................................... 20
Failure code [CA778] Trouble in engine Bkup speed sensor ...................................................... 22
Failure code [CA1228] Trouble in EGR valve servo 1................................................................. 24
Failure code [CA1625] Trouble in EGR valve servo 2................................................................. 25
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit ................................. 26
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit.............................. 28
Failure code [CA1628] Trouble in bypass valve servo 1 ............................................................. 29
Failure code [CA1629] Trouble in bypass valve servo 2 ............................................................. 30
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor.................................. 32
Failure code [CA1632] Abnormally low signal in bypass valve lift sensor ................................... 34
Failure code [CA1633] Trouble in KOMNET ............................................................................... 36
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor.............................. 38
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor ............................ 40
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply ....................... 42
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply ......................... 44
8 HM400-2
Failure code [CA2249] Low pressure in supply pump 2.............................................................. 44

Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor ........................ 46
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor.......................... 48
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit ..................................... 50
Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit ................................. 52
Failure code [CA2555] Disconnection in intake air heater relay ................................................. 52
Failure code [CA2556] Short circuit in intake air heater relay ..................................................... 54
Failure code [DAF9KM] Wrong connection of connector ............................................................ 3
Failure code [DAFRKR] Trouble in CAN communication (machine monitor) .............................. 4
Failure code [DAQ0KK] Lowering of source voltage ................................................................... 6
Failure code [DAQ0KT] Trouble in non-volatile memory............................................................. 8
Failure code [DAQ2KK] Trouble in solenoid power supply system ............................................. 10
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller)................. 12
Failure code [DAQRKR] Trouble in CAN communication (Transmission controller) ................... 14
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ................... 16
Failure code [DB10KT] Trouble in non-volatile memory.............................................................. 16
Failure code [DB12KK] Trouble in solenoid power supply system ............................................. 18
Failure code [DB13KK] Lowering of battery direct voltage.......................................................... 20
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)......................... 22
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) ........................... 22
Failure code [DB1RKR] Trouble in CAN communication (Retarder controller) ........................... 24
Failure code [DB2RKR] Trouble in CAN communication (Engine controller).............................. 26
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal.................... 28
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve .................................................. 30
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve................................................... 31
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve ................................................. 32
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve ................................................ 33
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve ................................................ 34
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve.......................................... 35
Failure code [DF10KA] Input of no lever signals......................................................................... 36
Failure code [DF10KB] Input of multiple lever signals ................................................................ 40
Failure code [DGF1KX] Transmission oil temperature out of range............................................ 44
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear).............................. 46
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) ........................... 48
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) .......................... 50
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) ........................ 52
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) ............................. 54
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)........................... 56
Failure code [DGR6KX] Steering oil temperature out of range ................................................... 58
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system ........... 4
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil
pressure sensor system .......................................................................................................... 6
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor..................................... 8
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system ................... 10
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system.................... 12
Failure code [DJF1KA] Disconnection in fuel level sensor system ............................................. 14
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS ............................... 16
Failure code [DK52KX] Trouble in dump lever potentiometer 1 .................................................. 18
Failure code [DK53L8] Trouble in dump lever potentiometer 2................................................... 20
Failure code [DK54KX] Trouble in dump positioner sensor ........................................................ 22
Failure code [DKH0KX] Pitch angle sensor signal out of range.................................................. 24
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system........... 26
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor.................................. 27
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor
system ..................................................................................................................................... 28
HM400-2 9
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor

system ..................................................................................................................................... 29
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system ........... 30
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system ......... 31
Failure code [DV00KB] Short circuit in buzzer output circuit....................................................... 32
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output
system ..................................................................................................................................... 34
Failure code [DW73KZ] Trouble in dump selector valve output system...................................... 36
Failure code [DW78KZ] Trouble in rear wheel BCV command output system............................ 38
Failure code [DW79KZ] Trouble in front wheel BCV command output system ........................... 40
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing
valve 1 ..................................................................................................................................... 42
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid
pressure reducing valve........................................................................................................... 44
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing
valve 2 ..................................................................................................................................... 50
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing
valve 1 ..................................................................................................................................... 52
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing
valve 2 ..................................................................................................................................... 60
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve............................ 4
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve .............................. 6
Failure code [DX13KY] Hot short in output circuit of dump EPC valve.................................... 8
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system......... 10
Failure code [DX15KZ] Trouble in front wheel differential lock command output system........ 12
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch
solenoid................................................................................................................................ 14
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch
solenoid................................................................................................................................ 16
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid.... 18
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid................... 19
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid ..................... 20
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid........................... 22
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid.......................... 24
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve........ 26
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve............. 28
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid ......................... 32
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve ....... 34
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve ............ 36
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid ........................ 40
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve ...... 42
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve ........... 44
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid ....................... 2
10 HM400-2
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve..... 4
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve .......... 6
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid........................ 10
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve...... 12
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve ........... 14
Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid ................. 18
Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve.... 20
Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve .... 22
Troubleshooting for electrical system (E-mode) SEN01116-01
Before troubleshooting for electrical system ............................................................................... 3
Information in troubleshooting table ............................................................................................ 9
E-1 Engine does not start (Starting motor does not turn) ............................................................ 10
E-2 Auto preheater does not operate.......................................................................................... 14
E-3 When starting switch is turned ON, machine monitor displays nothing ................................ 18
E-4 When starting switch is turned OFF, machine monitor cannot be operated ......................... 20
E-5 Alarm buzzer does not stop sounding .................................................................................. 22
E-6 Machine monitor does not normally display gauges, caution lamps, and character
display section ......................................................................................................................... 23
E-7 Display of character display section cannot be changed...................................................... 24
E-8 Power mode selection function does not operate normally .................................................. 28
E-9 AISS function does not operate normally ............................................................................. 30
E-10 Right and left differential lock function does not operate normally
(Differential lock-up specification)............................................................................................ 32
E-11 Interaxle differential lock-up function does not operate normally........................................ 36
E-12 Display of seat belt caution lamp is abnormal .................................................................... 38
E-13 Turn signal lamps and pilot lamps do not operate normally ............................................... 40
E-14 Night lighting is abnormal ................................................................................................... 45
E-15 Backup lamp and backup buzzer operate abnormally........................................................ 51
E-16 Emergency steering system does not operate ................................................................... 55
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01117-00
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 3
Information in troubleshooting table ........................................................................................ 3
H-1 Machine does not start ..................................................................................................... 4
H-2 Travel is not smooth (Machine hunts)............................................................................... 6
H-3 Lockup is not reset............................................................................................................ 6
H-4 Start shock and gear shift shock are abnormally large ..................................................... 7
H-5 Gear is not shifted up........................................................................................................ 8
H-6 Travel speed or power is low ............................................................................................ 10
H-7 Start and gearshift time lag is large .................................................................................. 14
H-8 Torque converter oil temperature is high .......................................................................... 16
H-9 Torque converter oil temperature is low............................................................................ 17
H-10 Front brake does not work fully....................................................................................... 18
H-11 Center brake does not work fully .................................................................................... 19
H-12 Rear brake does not work fully ....................................................................................... 20
H-13 Steering wheel is heavy .................................................................................................. 21
H-14 Steering wheel does not move........................................................................................ 22
H-15 Steering wheel waggle.................................................................................................... 23
H-16 Dump body raising speed is low ..................................................................................... 24
H-17 Dump body does not move............................................................................................. 25
H-18 Hydraulic drift of dump body is large .............................................................................. 26
Troubleshooting of engine (S-mode) SEN01118-01
Method of using troubleshooting chart ........................................................................................ 4
S-1 Starting performance of engine is poor................................................................................. 8
S-2 Engine does not start............................................................................................................ 10
S-3 Engine does not pick up smoothly........................................................................................ 14
S-4 Engine stops during operation .............................................................................................. 15
S-5 Engine does not rotate smoothly .......................................................................................... 16
HM400-2 11
S-6 Engine lack output (or lacks power)...................................................................................... 17

S-7 Exhaust gas is black (incomplete combustion)..................................................................... 18
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................... 20
S-9 Oil becomes dirty quickly ...................................................................................................... 21
S-10 Fuel consumption is excessive ........................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................. 23
S-12 Oil pressure drops .............................................................................................................. 24
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 26
S-14 Coolant temperature becomes too high (Overheating)....................................................... 28
S-15 Abnormal noise is made ..................................................................................................... 29
S-16 Vibration is excessive ......................................................................................................... 30
50 Disassembly and assembly

General information on disassembly and assembly SEN01442-03
How to read this manual.............................................................................................................. 2
List of adhesives.......................................................................................................................... 4
Special tool list............................................................................................................................. 7
Sketches of special tools............................................................................................................. 13
Removal and installation of fuel supply pump ............................................................................. 2
Removal and installation of engine assembly ............................................................................. 5
Removal and installation of cylinder head assembly................................................................... 13
Removal and installation of fuel injector assembly...................................................................... 26
Removal and installation of radiator assembly............................................................................ 32
Removal and installation of cooling assembly............................................................................. 36
Removal and installation of aftercooler ....................................................................................... 40
Removal and installation of engine front seal.............................................................................. 43
Removal and installation of engine rear seal .............................................................................. 45
Removal and installation of output shaft assembly ..................................................................... 2
Disassembly and assembly of output shaft assembly ................................................................. 6
Removal and installation of transmission and front differential assembly ................................... 9
Disconnection and coupling of front differential and transmission .............................................. 17
Disassembly and assembly of torque converter assembly ......................................................... 18
Disassembly and assembly of transmission assembly ............................................................... 26
Disassembly and assembly of front differential assembly ........................................................... 2
Removal and installation of center differential assembly............................................................. 19
Disassembly and assembly of center differential assembly ........................................................ 22
Removal and installation of rear differential assembly ................................................................ 37
Disassembly and assembly of rear differential assembly............................................................ 39
Removal and installation of front final drive and brake assembly ............................................... 2
Disassembly and assembly of front final drive and brake assembly ........................................... 4
Removal and installation of center final drive and brake assembly............................................. 17
Disassembly and assembly of center final drive and plate assembly ......................................... 19
Removal and installation of rear final drive and brake assembly ................................................ 28
Disassembly and assembly of rear final drive and brake assembly............................................ 30
Removal and installation of center axle assembly ...................................................................... 40
Removal and installation of rear axle assembly .......................................................................... 43
Undercarriage and frame SEN01447-02
Removal and installation of front suspension cylinder assembly ................................................ 2
Removal and installation of rear suspension cylinder assembly ................................................. 4
Removal and installation of equalizer bar assembly ................................................................... 5
Removal and installation of front wheel assembly ...................................................................... 7
Removal and installation of rear front wheel assembly ............................................................... 8
12 HM400-2
Removal and installation of rear rear wheel assembly................................................................ 8

Removal and installation of hitch frame assembly ...................................................................... 9
Disassembly and assembly of hitch frame.................................................................................. 15
Removal and installation of body assembly ................................................................................ 18
Disassembly and assembly of steering valve ............................................................................. 2
Removal and installation of flow amplifier valve assembly ......................................................... 12
Removal and installation of hoist valve assembly ....................................................................... 14
Disassembly and assembly of hoist valve assembly .................................................................. 16
Disassembly and assembly of steering cylinder assembly ......................................................... 18
Disassembly and assembly of hoist cylinder assembly .............................................................. 24
Removal and installation of operator's cab ................................................................................. 2
Removal and installation of operator's cab glass (Stuck glass) .................................................. 7
Disassembly and assembly of operator’s seat assembly............................................................ 13
Removal and installation of air conditioner unit assembly .......................................................... 23
Electrical system SEN01450-02
Removal and installation of retarder controller assembly............................................................ 2
Removal and installation of transmission controller assembly .................................................... 4
Removal and installation of engine controller assembly ............................................................. 6
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00533-02
Power train hydraulic circuit diagram .......................................................................................... 3
Steering and hoist hydraulic circuit diagram................................................................................ 5
Brake hydraulic circuit diagram ................................................................................................... 7
Brake cooling hydraulic circuit diagram....................................................................................... 8
Differential lock hydraulic circuit diagram .................................................................................... 9
Electrical diagrams and drawings SEN00534-04
Electrical circuit diagram for inside cab (1/4) .............................................................................. 3
Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188........................................ 5
Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up........................................ 7
Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188........................................ 9
Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up........................................ 11
Electrical circuit diagram for inside cab (4/4) .............................................................................. 13
Electrical circuit diagram for outside cab (1/3) ............................................................................ 15
Electrical circuit diagram for payload meter ................................................................................ 21
Connectors table and arrangement drawing ............................................................................... 23
HM400-2 13
HM400-2 Articulated dump truck

Form No. SEN00512-09
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 01-09 (02)
14 HM400-2
SEN00513-04
HM400-2

HM400-2 2001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
HM400-2 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
2 HM400-2
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
HM400-2 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 HM400-2
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
HM400-2 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 HM400-2
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
HM400-2 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 HM400-2
Explanation of terms for maintenance standard 1

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
HM400-2 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 HM400-2
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
HM400-2 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 HM400-2
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
HM400-2 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 HM400-2
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
HM400-2 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 HM400-2
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
HM400-2 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 HM400-2
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
HM400-2 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 HM400-2
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
HM400-2 21
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 HM400-2
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
HM400-2 23
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 HM400-2
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
HM400-2 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 HM400-2
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
HM400-2 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 HM400-2
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
HM400-2 29
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 HM400-2
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
HM400-2 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 HM400-2
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
HM400-2 33
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 HM400-2
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
HM400-2 35
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 HM400-2
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
HM400-2 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 HM400-2
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
HM400-2 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 HM400-2
HM400-2 41

© 2008 KOMATSU
All Rights Reserved
42 HM400-2
SEN00515-01
HM400-2

HM400-2 2001 and up
01 Specification 1
Specification and technical data
Specification drawings .................................................................................................................................... 2
Specifications .................................................................................................................................................. 3
Weight table .................................................................................................................................................... 6
Fuel, coolant and lubricants ............................................................................................................................ 7
HM400-2 1
SEN00515-01 01 Specification
Specification drawings 1
2 HM400-2
Specifications 1
Machine model HM400-2
Serial Numbers 2001 and up
Unloaded kg 32,460
Max. payload kg 37,000
Overall weight kg 68,960
Unloaded (front wheel) kg 17,885
Weight
(center wheel) kg 7,401

(rear wheel) kg 7,134
Weight
Fully loaded (front wheel) kg 19,929
(center wheel) kg 24,688
(rear wheel) kg 24,412
Struck m3 16.5
Dump body capacity
Heaped (2:1) m 3 22.3
Performance
Max. travel speed km/h 58.6

Gradeability (tan ) 0.51
Min turning radius (front wheel/rear wheel) (S) mm 8,712/4,168
Dumping angle (angle to ground) deg 70
Overall length (A) mm 11,310

Overall width (B) mm 3,450
Overall height (C) mm 3,720
Body width (D) mm 3,450
Front over bank (E) mm 3,170
Wheelbase (front wheel - center wheel) (F) mm 4,350
Wheelbase (center wheel - rear wheel) (G) mm 1,970
Flexural center - front wheel (H) mm 1,350
Front tires mm 2,690

Tread (J) Center tires mm 2,690
Rear tires mm 2,690
Front wheel mm 3,450

Entire width of tire (K) Rear front wheel mm 3,450
Dimensions
Rear rear wheel mm 3,450
Approach angle (L) deg 25

Front wheel mm 670
Minimum ground clear-
Rear front wheel mm 625
ance (M)
Rear rear wheel mm 625
Ground Clearance (N) mm 605
Minimum ground clearance (dump body lower edge) (P) mm 720
Dump body loading height (Q) mm 2,790

Dump body height (unloaded) (R) 7,130
Rear axis - dump body rear edge (unloaded) (R2) mm 620
Rear axis - axis pin (R3) 1,820
Cab width (T) mm 1,594
Body length (U) mm 5,392
HM400-2 3
Model Komatsu SAA6D140E-5
Type 4-cycle, water-cooled, in-line 6 cylinder, direct

injection, with turbocharger and air-cooled
after-cooler
No. of cylinders - Bore x stroke mm 6 -140 x 165
Piston displacement l{cc} 15.24 {15,240}
Engine
Flywheel horsepower kW/rpm{HP/rpm} 338/2,000 {453/2,000}

Max. torque Nm/rpm{kgm/rpm} 2,090/1,400 {213/1,400}
Fuel consumption (rated) g/kWh{g/HPh} 213 {159}
Starting motor 11kW
Alternator 24V 60A
Battery 12V 160Ah x 2
3-element, 1-stage, 2-phase

Type
Torque converter Hydraulically-actuated, wet-type, single-disc
Lock-up clutch
clutch
TORQFLOW multiple-axle transmission, fully

Type automatic, electrically-hydraulically actuated,
Transmission
Power train
No. of speeds force-feed type pump lubrication type

F6, R2
Type Straight bevel gear, splash lubrication

Reduction gear Reduction ratio 3.417
Differential type Straight bevel gear, splash lubrication
Type Planetary gear, splash lubrication

Final drive
Reduction ratio 4.941
Travel system
Type Fully hydraulic
Front axle Independent suspension (MacPherson type)

Axle type Center axle Independent suspension (MacPherson type)
Suspension
Rear axle Independent suspension (MacPherson type)
Front axle Hydropneumatic type

Suspension method
Rear axle Hydropneumatic type
Front tire 29.5 R25 x 2

Size and no. Center tire 29.5 R25 x 2
Tires
Rear tire 29.5 R25 x 2
kPa
Tire inflation pressure 0.372 {3.8}
{kg/cm2}
4 HM400-2
Independent front and center system brake, sealed,

Front wheel wet- type, multiple disc, hydraulically operated type
Main brake
Center wheel Independent front and center system brake, sealed,
Brakes
wet- type, multiple disc, hydraulically operated type
Parking brake Spring-boosted, caliper disc type
Independent front and center system brake, sealed,

Retarder
wet- type, multiple disc, hydraulically operated type
For steering, hoist

Type Gear pump
Discharge amount (l /min) 218 + 218
(when engine is at rated speed of 2,000 rpm)
For hoist control
Type Gear pump
Discharge amount (l /min) 18.5
For transmission, brake cooling
Type Gear pump
Discharge amount (l /min) 180
For brake cooling
Hydraulic pump, motor
Type Gear pump

For brake
Type Gear pump
Hydraulic system

For front differential lock-up
Type Gear pump
For differential lock-up motor
Type Gear pump
Discharge amount (l /min) 28.1
For center and rear differential lock-up
Type Gear pump
Discharge amount (l /min) 74 x 2
(when motor is at speed of 1,000 rpm)
Hoist cylinder
Type 2-stage piston type
(only 2nd stage double-acting)
Cylinders
No. - bore (1st-2nd) x stroke 2-(160mm-120mm) x 3,232mm

Steering cylinder
Type Piston type, double acting
No. - bore x stroke 2-120mm x 525mm
HM400-2 5
Weight table 1
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine assembly 1,710

Output shaft assembly 88
Cooling assembly 284
Fuel tank (individual part) 244
Torque converter assembly 282
Transmission assembly 1,450
Drive shaft assembly 295
Front axle assembly 1,505
Differential 428
Final drive 1,077
Center axle assembly 1,898
Differential 397
Final drive 1,060
Rear axle assembly 1,772
Differential 265
Final drive 1,064
Front suspension cylinder 91.5
Rear suspension cylinder 78.9
Oscillation hitch assembly 851
Front frame 1,666
Rear frame 2,094
Cab (interior components) 1,090
Operator’s seat 65
Steering cylinder (one side) 66.8
Hoist cylinder (one side) 254
Flow amp valve 29
Hoist valve 63
Hydraulic tank 244
Hydraulic pump (SDR(30)63 + SA(1)25) 31.4
Hydraulic pump (SDR(30)80 + SB(1)12 + 8) 24.0
Hydraulic pump (SDR(30)100 + 100 + SB(1)8) 42.2
Hydraulic pump (SDR(30)80) 18.7
Body assembly 4,380
6 HM400-2
Fuel, coolant and lubricants 1

a Regarding the details of notes (note 1, note 2, ...), refer to "Operation & Maintenance Manual".
HM400-2 7
Reservoir Transmission
Front Rear Front
Engine case Hydraulic
suspension suspension differential
oil pan (Incl. brake tank
(each) (each) Case
Capacity oil tank)
l 56 270 267 6 4.2 22.5

Specified
US gal 14.79 71.33 70.54 1.59 11.09 5.94
l 50 115 180 6 4.2 22.5

Refill
US gal 13.21 30.38 47.56 1.59 11.09 5.94
Reservoir
Front final Center Center final Rear Rear final
Cooling
drive case differential drive case differential drive case Fuel tank
system
(each) Case (each) Case (each)
Capacity
l 6.5 39.5 5.5 35 5.5 500 114.5

Specified
US gal 1.72 10.44 1.45 9.25 1.45 132.1 30.25
l 6.0 39.5 5.0 35 5.0 – 106.5

Refill
US gal 1.59 10.44 1.32 9.25 1.32 – 28.14
8 HM400-2
HM400-2 9

© 2007 KOMATSU
All Rights Reserved
10 HM400-2
SEN00517-01
HM400-2

HM400-2 2001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Radiator, oil cooler, aftercooler ....................................................................................................................... 2
Output shaft .................................................................................................................................................... 3
HM400-2 1
SEN00517-01 10 Structure, function and maintenance standard
Radiator, oil cooler, aftercooler 1
1. Aftercooler Specifications
2. Water filler Radiator
3. Reservoir tank • Core type: CF4-5
4. Upper tank • Total heat dissipation area: 90.68m2
5. Lower tank Torque converter oil cooler
6. Oil cooler (steering, torque converter) • Core type: PTO-LS
7. Sub tank • Total heat dissipation area: 4.0655m2
Steering oil cooler
A: From thermostat • Core type: PTO-OL
B: To water pump • Total heat dissipation area: 0.896m2
C: From brake
D: To oil filter
E: From hoist valve
F: To hydraulic tank
G: From water pump
2 HM400-2
Output shaft 1
1. Rubber cushion Function

2. Outer body The output shaft is installed to the engine fly-
3. Flange wheel,and absorbs the twisting vibration caused by
4. Shaft changes in the engine torque.
5. Coupling
6. Inner body
7. Cover
HM400-2 3
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
1
flywheel and bearing
0 0 -0.030 –
80 0.02
-0.013 -0.030 0.013
Clearance between shaft -0.009 0 -0.003 – Replace
2 40 0.10
and bearing -0.025 -0.012 0.025
Clearance between bearing 0 -0.006 -0.028 –
3 120 –
and cover -0.015 -0.028 0.009
Clearance between bearing 0.012 0 -0.027 –
4 65 0.025
and shaft -0.007 -0.015 0.007
Weaar of oil seal contact sur- Standard size Repair limit Repair or
5
face of coupling 95 94.7 replace
Standard backlash Backlash limit

6 Backlash at spline
0.099 – 0.202 0.4
Standard backlash (Dimension
Deformastion of Original dimension : Lo Replace
at smallest width : L)
7 rubber cushion
75 67
External Without cranks
4 HM400-2
HM400-2 5

© 2007 KOMATSU
All Rights Reserved
6 HM400-2
SEN00518-01
HM400-2

HM400-2 2001 and up

Power train, Part 1
Power train skeleton ....................................................................................................................................... 2
Torque converter and transmission hydraulic piping....................................................................................... 6
Brake cooling oil control valve (BCV).............................................................................................................. 8
Power train pump............................................................................................................................................ 9
Torque converter ........................................................................................................................................... 12
Transmission................................................................................................................................................. 18
Transmission control valve............................................................................................................................ 46
ECMV............................................................................................................................................................ 47
Main relief, torque converter relief valve ....................................................................................................... 54
HM400-2 1
Power train skeleton 1

(Machine with differential lock differential)
2 HM400-2
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling and brake system pump (SDR(30)63+SA(1)12)
5. Power train, front brake cooling, differential lock control pump (SDR(30)80+SB(1)12+8)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SDR(30)100+100+SB(1)8)
9. Transmission
10. Center drive shaft
11. Oscillation hitch
12. Drive shaft (hitch)
13. Front differential
14. Front differential lock
16. Tire
17. Final drive (front)
18. Brake (front)
19. Rear drive shaft (front)
20. Center differential
21. Center differential lock
22. Tire
23. Final drive (center)
24. Brake (center)
25. Rear drive shaft (rear)
26. Rear differential
27. Rear differential lock
28. Tire
29. Final drive (rear)
30. Brake (rear)
31. Interaxle differential lock
HM400-2 3
(Machine with limited slip differential)
4 HM400-2
1. Engine
2. Output shaft
4. Brake cooling and brake system pump (SDR(30)63+SA(1)12)
5. Power train pump (SDR(3)80)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SDR(30)100+100+SB(1)8)
9. Transmission
10. Center drive shaft
11. Oscillation hitch
12. Drive shaft (hitch)
14. Front limited slip differential
16. Tire
17. Final drive (front)
18. Brake (front)
19. Rear drive shaft (front)
21. Center limited slip differential
22. Tire
23. Final drive (center)
24. Brake (center)
25. Rear drive shaft (rear)
27. Rear limited slip differential
28. Tire
29. Final drive (rear)
30. Brake (rear)
31. Interaxle differential lock
HM400-2 5
Torque converter and transmission hydraulic piping 1
6 HM400-2
1. Engine
2. Torque converter
3. Transmission
4. Oil cooler
5. Power train, brake cooling return filter
6. Rear brake cooling and brake system pump (SDR(30)63+SA(1)25)
7. Brake system tank
8. Power train, front brake cooling, differential control pump (SDR(30)80+SB(1)12+8)
9. Transmission oil filter
10. Front brake cooling valve
11. Center brake cooling valve
HM400-2 7
Brake cooling oil control valve (BCV) 1
1. Pilot relief valve assembly Function

2. Body • When the retarder is not being used, this valve
3. Solenoid valve bypasses part of the brake cooling oil to reduce
4. Main valve spool the power loss when traveling.
• The main valve spool is actuated by switching
S: To transmission the solenoid vavle ON/OFF.
Q: From transmission If any abnormal pressure is generated in the hy-
R: To oil cooler draulic circuit, the pilot relief valve is actusted,
and this actuates the main relief valve, so the
brake cooling valve also acts as an unload
valve.
8 HM400-2
Power train pump 1

Power train, front brake cooling, differential lock pump (Machine with differential lock differential)
SDR(30)80+SB(1)12+8
Unit: mm
Model Standard clearance Clearance limit
SDR(30)-80 0.16 – 0.20 0.24
1 Side clearance
SB(1)-12
0.10 – 0.15 0.19
SB(1)-8
Clearance between inside SDR(30)-80 0.06 – 0.13
diameter of plain bearing and
2 SB(1)-12 0.20 Replace
outside of diameter of gear 0.06 – 0.12
shaft SB(1)-8
Model Standard size Tolerance Repair limit
3
SDR(30)-80 0
Depth for knocking in pin 10
4 SB(1)-12 -0.5 –
5 SB(1)-8 9.2 ±0.3
6 Rotating torque of spline shaft 10.8 – 21.5 Nm {1.1 – 2.2 kgm}
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
Discharge amount (rpm) (l/min) –
(kg/cm2)} (l/min)
– Oil: EO10-CD
Oil temperature: 45–55°C SDR(30)-80 184.5 170.4
20.6
SB(1)-12 2,500 26.7 24.5
{210}
SB(1)-8 17.2 15.8
HM400-2 9
Brake cooling, brake system pump

SDR(30)63+SA(1)25
Unit: mm

1 Side clearance SDR(30)-63 0.16 – 0.20 0.24
SA(1)-25 0.10 – 0.15 0.19
Clearance between inside SDR(30)-63 0.06 – 0.13
2 0.20 Replace
outside of diameter of gear SA(1)-25 0.06 – 0.12
shaft
3 Depth for knocking in pin SDR(30)-63 0
10 –
SA(1)-25 -0.5

Delivery Standard
Rotating Delivery
pressure delivery
Discharge amount {MPa amount –
(rpm) (l/min)
– Oil: EO10-CD (kg/cm2)} (l/min)
Oil temperature: 45–55°C
SDR(30)-63 20.6 145.8 134.7
2,500
SA(1)-25 {210} 56.5 50.8
10 HM400-2
Transmission pump (Machine with limited slip differential)

SDR(30)80
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.16 – 0.20 0.24
Clearance between inside
2 0.06 – 0.13 0.20
outside of diameter of gear Replace
shaft
3 Insertion depth of pin Standard size Tolerance Repair limit
0
4 Rotating torque of spline shaft 10 –
-0.5
Delivery Standard
Rotating Delivery
pressure delivery
Discharge amount speed amount limit
{MPa amount
– Oil: EO10-CD (rpm) (l/min) –
(kg/cm2)} (l/min)
20.6
2,500 184.5 170.4
{210}
HM400-2 11
Torque converter 1
Unit: mm

Clearance between PTO gear size Shaft Hole clearance limit
1
and bearing
+0.018 0 -0.030 – Replace
50 —
+0.002 -0.012 -0.002
Clearance between bearing and 0 +0.004 -0.018 –
2 90 —
case -0.015 -0.018 0.019
3. Power train, front brake cooling, differential lock Specifications

control pump installation port Type: 3-element, 1-stage, 2-phase
4. Steering, hoist control pump installation port with modulation and lockup clutch
5. Brake cooling, brake system pump installation Lockup clutch: wet type single-disc clutch
port hydraulic control
6. PTO gear (number of teeth: 91) (with modulation valve)
Stall torque ratio: 2.63
12 HM400-2
1. Coupling 10. Sleeve

2. Input shaft (number of teeth: 108) 11. Inner race
3. Case 12. Free wheel
4. Drive case 13. Stator
5. Turbine 14. Lockup clutch disc
6. Outer race 15. Lockup clutch piston
7. Pump 16. Lockup clutch housing
8. Retainer 17. Retainer
9. Stator shaft
HM400-2 13
14 HM400-2
Unit: mm
Standard size Tolerance Repair limit

Outer diameter of the oil seal
1 0
contact surface of the coupling 95 94.8
-0.087
Inner diameter of the seal ring
+0.025
2 contact surface of the input 35 35.5
0
shaft
+0.097
3 contact surface of the clutch 420 420.5
0
housing
+0.081
4 contact surface of the clutch 295 295.1
0
piston
Inner diameter of the seal ring +0.040
5 135 135.5
contact surface of the retainer 0
+0.030
6 contact surface 70 70.5
0 Replace
of the sleeve
Wear of the clutch -0.01

Width 5 4.5
7 housing -0.04
seal ring Thickness 7 ±0.15 6.85
Inner diameter of race
8 127.844 ±0.013 127.874
free wheel transmission surface
Outer diameter of stator shaft
9 108.883 ±0.013 108.853
free wheel transmission surface
Inner diameter of sliding por- +0.015
10 109 109.08
tion of bushing 0
Thickness of sliding portion of 0
11 5 4.5
bushing -0.1
12 Thickness of the clutch disc 5.4 ±0.1 4.9
Backlash between
13 0.17 - 0.45
input shaft and PTO gear
HM400-2 15
Power transmission route
When lockup clutch is “disengaged“ When lockup clutch is “engaged“
Drive case (4) is disconnected from boss (7) and Drive case (4) is connected to boss (7) and turbine
turbine (6) and lockup torque converter works as an (6) and lockup torque converter is locked up.
ordinary torque converter.
The power from engine
The power from engine O
O Drive shaft
Drive shaft O
O Coupling (1)
Coupling (1) O
O Input shaft (2), clutch housing (3), drive case (4)
Input shaft (2), clutch housing (3), drive case (4) and pump (5) rotate together
and pump (5) rotate together O
O Lockup clutch is engaged
Oil is used as medium O
O Turbine (6) and boss (7)
Turbine (6) and boss (7) O
O Transmission input shaft (8)
Transmission input shaft (8)
• The power transmitted to input shaft (2) is also
• The power transmitted to input shaft (2) is also used as power for driving the pump after being
used as power for driving the pump after being transmitted through PTO gear.
transmitted through PTO gear.
16 HM400-2
Oil flow
• The oil flows through the main relief valve and its
pressure is reduced to below the set pressure by
the torque converter relief valve. It then flows
into inlet port (A), goes through the oil passages
of stator shaft (1), and flows into pump (2).
• The oil is given centrifugal force by pump (2) and
flows into turbine (3) to transfer its energy to tur-
bine (3).
• The oil from turbine (3) is sent to stator (4) and
flows into pump (2) again. However, part of the
oil passes between turbine (3) and stator (4) and
is sent from outlet port (B) to the oil cooler to be
cooled. It is then used to lubricate the transmis-
sion.
HM400-2 17
Transmission 1
18 HM400-2
A: To front brake Outline

B: From return filter • The transmission adopted is a “forward 6-gear
C: To power train, front brake cooling, differential speed and reverse 2-gear speed“ transmission
lock control pump which consists of the counter-shaft type, con-
D: To brake cooling, brake system pump stant mesh spur gear mechanisms and the disc
clutches.
1. Transmission case (front) • The transmission selects one rotation direction
2. Transmission case (rear) and rotation speed by fixing the counter-shaft
3. Transmission intermediate shaft speed sensor type, constant mesh spur gear mechanisms and
4. Differential input speed sensor 2 out of 6 sets disc clutch with the oil pressure by
5. Oil filler tube mounting port ECMV operation.
6. Power train, lubricating oil temperature sensor • The transmission transfers the power received
7. Drain plug by the transmission input shaft to the output
8. Drain valve shaft while changing the gear speed (forward
1st-6th or reverse 1st-2nd) by any combination
of the FL, FH, R clutches and 3 speed clutches.
• The gear is automatically shifted with automatic
transmission based on the engine speed chang-
es.
Number of plates and disks used
Number of
Clutch No. Number of discs
plates
FL clutch 12 11
R clutch 12 11
FH clutch 10 9
1st clutch 12 11
3rd clutch 8 7
2nd clutch 14 13
Combinations of clutches at respective gear

speeds and reduction ratio
Gear speed Operated clutches Reduction ratio

Forward 1st FL x 1st 6.061
Forward 2nd FH x 1st 3.957
Forward 3rd FL x 2nd 2.574
Forward 4th FH x 2nd 1.680
Forward 5th FL x 3rd 1.094
Forward 6th FH x 3rd 0.714
Neutral — —
Reverse 1st R x 1st 5.851
Reverse 2nd R x 2nd 2.484
HM400-2 19
Unit: mm

Clearance between bearing and size Shaft Hole clearance limit
1
case
+0.032 0 -0.047 – Replace
70 —
+0.002 -0.015 -0.002
Clearance between 0 -0.036 -0.061 –
2 125 —
R idler gear and bearing -0.018 -0.061 -0.018
3. Transmission input shaft speed sensor

4. Torque converter outlet oil temperature sensor
5. Transmission control valve
6. Main relief, torque converter relief valve
7. Torque converter intermediate oil pressure sensor
8. R idler gear (Number of teeth: 35)
9. Strainer
10. Lubricating oil relief valve
A: From transmission oil filter
20 HM400-2
1. R clutch 8. Lower shaft

2. 1st clutch 9. 3rd clutch
3. 2nd clutch 10. Upper shaft
4. Differential lock clutch 11. FH clutch
5. Rear output shaft 12. Input shaft
6. Rear coupling 13. FL clutch
7. Front output shaft 14. Torque converter
HM400-2 21
22 HM400-2
Unit: mm

Clearance between FL, R clutch size Shaft Hole clearance limit
1
bearing and case (front)
0 0 -0.040 –
160 —
-0.025 -0.040 0.025
Clearance between FL, R clutch 0 0 -0.040 –
2 160 —
bearing and case (rear) -0.025 -0.040 0.025
Clearance between FH, 1st 0 0 -0.040 –
3 160 —
clutch bearing and case (front) -0.025 -0.040 0.025
Clearance between FH, 1st 0 0 -0.040 –
4 160 —
clutch bearing and case (rear) -0.025 -0.040 0.025
Clearance between 2nd, 3rd 0 -0.012 -0.052 –
5 160 —
clutch bearing and case (front) -0.025 -0.052 0.013
Clearance between 2nd, 3rd 0 -0.017 -0.052 –
6 160 —
clutch bearing and cage (rear) -0.025 -0.052 0.008
Clearance between differential
0 -0.014 -0.060 –
7 lock clutch bearing and case 230 —
-0.030 -0.060 0.016
(front)
Clearance between differential
0 -0.014 -0.060 –
8 lock clutch bearing and cage 230 —
-0.030 -0.060 0.016
(rear)
Clearance between front output 0 +0.018 -0.007 –
9 140 —
bearing and cage -0.018 -0.007 0.036
Clearance between front output +0.045 0 -0.065 –
10 90 — Replace
bearing and spacer +0.023 -0.020 -0.023
Width of the input shaft seal ring
11 +0.18
groove 2.5 2.7
+0.10
Width of the input shaft seal ring +0.076
12 3.2 3.5
groove 0
Inner diameter of seal ring
+0.050
contact surface of input, upper 50 50.1
0
and lower shafts (rear)
13
Width of seal ring grooves of
+0.076
input, upper and lower shafts 3.2 3.5
0
(rear)
Inner diameter of the seal ring +0.040
140 140.1
contact surface of the sleeve 0
14
Width of the sleeve seal ring +0.15
4.5 5.0
groove +0.10
+0.035
contact surface of the front 85 85.1
0
15 output shaft
Width of the front output shaft +0.15
3.0 3.3
seal ring groove +0.10
Outer diameter of the oil seal
0
16 contact surface of the rear 120 119.8
-0.087
coupling
HM400-2 23
FL, R clutch
A: R clutch oil port C: Lubrication oil port

B: FL clutch oil port D: Lockup clutch oil port
1. Input shaft 5. FL, R cylinder

2. Input gear (Number of teeth: 43) 6. R clutch
3. FL clutch gear (Number of teeth: 33) 7. R clutch gear (Number of teeth: 25)
4. FL clutch
Unit: mm

8
FL, R shaft and bearing (front)
+0.071 0 -0.086 –
75 —
+0.061 -0.015 -0.061
Clearance between +0.071 0 -0.086 –
9 75 —
FL, R shaft and bearing (rear) +0.061 -0.015 -0.061
10 Clutch plate Thickness 2.0 ±0.05 1.8
Strain — 0.05 0.15 Replace
Thickness 3.2 ±0.08 2.75

11 Clutch disc
Strain — 0.10 0.25
Wave spring load 1,270 N 115 N 1,090 N
12
[Test height: 3.8 mm] {130 kg} {11.7 kg} {111 kg}
Thickness of thrust washer
13 4 ±0.2 3.7
(FL clutch)
14 4 ±0.2 3.7
(R clutch)
24 HM400-2
FH, 1st clutch
A: 1st clutch oil port C: Lubrication oil port

B: FH clutch oil port
1. FH clutch gear (Number of teeth: 57) 5. 1st clutch gear (Number of teeth: 30)
2. FH clutch 6. Upper gear (Number of teeth: 49)
3. FH, 1st cylinder (Number of teeth: 67) 7. Upper shaft
4. 1st clutch
Unit: mm

8
FH, 1st shaft and bearing (front)
+0.071 0 -0.086 –
75 —
+0.051 -0.015 -0.051
9 75 —
FH, 1st shaft and bearing (rear) +0.051 -0.015 -0.051
Strain — 0.05 0.15 Replace
Thickness 3.2 ±0.08 2.75

11 Clutch disc
Strain — 0.10 0.25
12
13 4 ±0.2 3.7
(FH clutch)
14 4 ±0.2 3.7
(1st clutch)
HM400-2 25
2nd, 3rd clutch
A: 3rd clutch oil port C: Lubrication oil port

B: 2nd clutch oil port
1. 3rd clutch gear (Number of teeth: 25) 5. 2nd clutch gear (Number of teeth: 43)
2. 3rd clutch 6: Lower gear (Number of teeth: 54)
3. 2nd, 3rd cylinder (Number of teeth: 62) 7. Lower shaft
4. 2nd clutch
Unit: mm

Clearance between size clearance limit
Shaft Hole
8 2nd, 3rd shaft and bearing
(front) +0.071 0 -0.086 –
75 —
+0.051 -0.015 -0.051
Clearance between
+0.071 0 -0.086 –
9 2nd, 3rd shaft and bearing 75 —
+0.051 -0.015 -0.051
(rear)
Replace
Strain — 0.05 0.15
Thickness 3.2 ±0.08 2.75
11 Clutch disc
Strain — 0.10 0.25
12
13 4 ±0.2 3.7
(3rd clutch)
14 4 ±0.2 3.7
(2nd clutch)
26 HM400-2
HM400-2 27
Differential lock clutch
A: Lubrication oil port
1. Front output shaft

2. Clutch hub
3. Housing
4. Differential lock clutch
5. Sun gear (Number of teeth: 40)
6. Planetary gear (Number of teeth: 20)
7. Ring gear (Number of teeth: 80)
8. Carrier
9. Output gear (Number of teeth: 78)
10. Rear output shaft
28 HM400-2
Unit: mm

11
housing and bearing
+0.052 0 -0.077 –
170 —
+0.027 -0.025 -0.027
12 170 —
output gear and bearing +0.040 -0.025 -0.040
13 130 —
housing and bearing -0.018 -0.052 0.006
14 75 —
front output shaft and bearing -0.007 -0.015 0.007
15 150 —
output gear and bearing (front) -0.015 -0.090 -0.035
16 150 —
output gear and bearing (rear) -0.015 -0.068 -0.013
Replace
17 100 —
rear output shaft and bearing +0.013 -0.015 -0.013
Strain — 0.05 0.15
Thickness 3.2 ±0.10 2.75
19 Clutch disc
Strain — 0.20 0.25
20
[Test height: 3.2 mm] {151 kg} {45 kg} {128 kg}
+0.030
contact surface 70 70.1
0
21 of the carrier
Width of the front output shaft
2.1 ±0.05 2.3
seal ring groove
HM400-2 29
Operation of the disc clutch
When clutch is “engaged“ (fixed) Clutch “disengaged“ (released)
• The oil sent from the ECMV flows through the oil • When the oil sent from the ECMV is shut off,
passage of shaft (1), is pressure-fed to the back pressure of the oil acting on the back face of pis-
side of piston (2), and pushes piston (2) to the ton (2) goes down.
right. • Piston (2) is pushed back to the left by the ten-
• Piston (2) compresses plates (3) and discs (4) sion of wave spring (7).
and the rotation of discs (4) is stopped by the • The friction force between plates (3) and discs
frictional force. (4) is eliminated and shaft (1) and clutch gear (5)
• As the internal teeth of disc (4) are meshed with are released.
the clutch gear (5), shaft (1) and cluch gear (5) • When the clutch is released, the oil in the back
transfer the power as a unit. side of piston is drained by the centrifugal force
• The oil is drained from oil drain hole (6), but the through oil drain hole (6) to prevent the clutch
drain amount is less than the amount of oil sup- from being partially applied.
plied, so there is no influence on the actuation of
the clutch.
a Oil drain hole (6) forms part of the structure of
only the 2nd, 3rd and differential lock clutches.
30 HM400-2
HM400-2 31
Forward 1st speed
32 HM400-2
FL clutch (4) and 1st clutch (12) are fixed hydraulically.
The power from the torque converter

O
Input shaft (1)
O
FL and R cylinders (2)
O
FL clutch (4)
O
FL clutch gear (6)
O
FH and 1st cylinders (9)
O
1st clutch (12)
O
1st clutch gear (13)
O
2nd and 3rd cylinders (15)
O
Lower gear (20)
O
Output gear (21)
(The operation when differential lock is turned
"OFF" is explained below)
O
Carrier (22)
O
Planetary gear (26)
O
Sun gear (27) Ring gear (28)
O O
Front output shaft (29) Rear output shaft (30)
a If the differential lock is "on", see Forward 2nd speed.
HM400-2 33
Forward 2nd speed
34 HM400-2
FH clutch (11) and 1st clutch (12) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
O
1st clutch (12)
O
O
O
Lower gear (20)
O
Output gear (21)
"ON" is explained below)
O
Carrier (22)
O
Front housing (23)
O
Differential lock clutch (24) Planetary gear (26)
O O
Clutch hub (25) Ring gear (28)
O O
a If the differential lock is "off", see Forward 1st speed.
HM400-2 35
Forward 3rd speed
36 HM400-2
FL clutch (4) and 2nd clutch (18) are fixed hydraulically.

O
Input shaft (1)
O
O
FL clutch (4)
O
FL clutch gear (6)
O
O
Upper gear (14)
O
2nd clutch gear (16)
O
2nd clutch (18)
O
O
Lower gear (20)
O
Output gear (21)
O
Carrier (22)
O
Planetary gear (26)
O
O O
HM400-2 37
Forward 4th speed
38 HM400-2
FH clutch (11) and 2nd clutch (18) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
O
Upper gear (14)
O
2nd clutch gear (16)
O
2nd clutch (18)
O
O
Lower gear (20)
O
Output gear (21)
O
Carrier (22)
O
Front housing (23)
O
O O
O O
HM400-2 39
Forward 5th speed
40 HM400-2
FL clutch (4) and 3rd clutch (19) are fixed hydraulically.

O
Input shaft (1)
O
O
FL clutch (4)
O
FL clutch gear (6)
O
O
3rd clutch gear (17)
O
3rd clutch (19)
O
O
Lower gear (20)
O
Output gear (21)
O
Carrier (22)
O
Planetary gear (26)
O
O O
HM400-2 41
Forward 6th speed
42 HM400-2
FH clutch (11) and 3rd clutch (19) are fixed hydraulically.

O
Input shaft (1)
O
Input gear (3)
O
FH clutch gear (10)
O
FH clutch (11)
O
O
3rd clutch gear (17)
O
3rd clutch (19)
O
O
Lower gear (20)
O
Output gear (21)
O
Carrier (22)
O
Front housing (23)
O
O O
O O
HM400-2 43
Reverse 1st speed
44 HM400-2
R clutch (5) and 1st clutch (12) are fixed hydraulically.

O
Input shaft (1)
O
O
R clutch (5)
O
R clutch gear (7)
O
R idler gear (8)
(Output rotation is reversed through R idler gear (8).)
O
Upper gear (14)
O
O
1st clutch (12)
O
O
O
Lower gear (20)
O
Output gear (21)
O
Carrier (22)
O
Planetary gear (26)
O
O O
HM400-2 45
Transmission control valve 1
A: Lockup clutch oil pressure pickup port Operation table of ECMV

B: 2nd clutch oil pressure pickup port ECMV
C: 3rd clutch oil pressure pickup port sgear FL FH R 1st 2nd 3rd L/U D/L
D: R clutch oil pressure pickup port speed
E: FL clutch oil pressure pickup port F1 Q Q Q Q
F: 1st clutch oil pressure pickup port F2 Q Q Q Q
G: FH clutch oil pressure pickup port F3 Q Q Q Q
H: Differential lock clutch oil pressure pickup port
F4 Q Q Q
F5 Q Q Q
1. Lockup clutch ECMV
F6 Q Q Q
2. 2nd clutch ECMV
3. 3rd clutch ECMV R1 Q Q Q
4. R clutch ECMV R2 Q Q Q
5. FL clutch ECMV N Q
6. Breather L/U: lockup clutch ECMV
7. 1st clutch ECMV D/L: differential lock clutch ECMV
8. FH clutch ECMV
9. Differential lock clutch ECMV Outline
10. Seat • Lockup clutch ECMV operates when traveling
11. Last chance filter forward at the speed higher than the set speed
of transmission controller.
• Differential lock clutch ECMV operates in the 3rd
or lower gear speeds.
46 HM400-2
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
For FL, FH, R, 1st, 2nd, 3rd clutches

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump Operated clutches Stamp of the nameplates
T: Drain
FL,FH,R,1st A*******
Dr: Drain
P1: Clutch oil pressure pickup port 2nd,3rd E*******
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)
HM400-2 47
Outline of ECMV ECMV and proportional solenoid

• The ECMV consists of 1 pressure control valve • For each ECMV, 1 proportional solenoid is in-
and 1 fill switch. stalled.
• Pressure control valve The proportional solenoid generates thrust
This valve receives the current sent from the shown below according to the command current
transmission controller with a proportional sole- from the controller.
noid, and then converts it into oil pressure. The thrust generated by the proportional sole-
• Fill switch noid is applied to the pressure control valve
This switch is detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
by controlling the command current to operate
1. Outputs a signal (a fill signal) to the controller to the pressure control valve to control the flow
notify that filling is completed when the clutch is and pressure of the oil.
filled with oil.
2. Keeps outputting signals (fill signals) to the con- Current - propulsion force characteristics of
troller to notify whether oil pressure is applied or proportional solenoid
not while oil pressure is applied to the clutch.
Propulsion force - hydraulic pressure character-

istics of proportional solenoid
Range A: Before shifting gear (When draining)

ECMV and fill switch
Range B: During filling
Range C: Pressure regulation • For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) If the clutch is filled with oil, the fill switch is
Point E: Start of filling turned “on“ by the pressure of the clutch. The oil
Point F: Finish of filling pressure is build up according to this signal.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “on“ during triggering (Range
D).
48 HM400-2
Operation of ECMV Before shifting gear (when draining) (Range A in

• ECMV is controlled with the command current chart)
sent from the controller to the proportional sole-
noid and the fill switch output signal.
The relationship between the proportional sole-
noid command current of ECMV, clutch input
pressure, and fill switch output signal is shown
below.
• Under the condition where any current is not

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
Also at this time, fill switch (5) is turned “off“ be-
cause oil pressure is not applied to pressure de-
Range A: Before shifting gear (When draining) tection valve (4).
Range B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “on“ during triggering (Range
D).
HM400-2 49
During filling (Range B in chart) Pressure regulation (Range C in chart)
• If current is applied to proportional solenoid (1) • If current flows in proportional solenoid (1), the
with no oil in the clutch, the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to current. This thrust of the solenoid is balanced
chamber (B) and pushes pressure control valve with the sum of the thrust generated by the oil
(3) to the left.This opens pump port (P) and pressure in clutch port and the tension of pres-
clutch port (A) to feed oil in the clutch. When the sure control valve spring (2), and then the pres-
clutch is filled with oil, pressure detection valve sure is settled.
(4) actuates to turn “on“ fill switch (5).
50 HM400-2
For lockup, differential lock clutch

a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch *1:
P: From pump Operated clutches Stamp of the nameplates
T: Drain Lockup,
Dr: Drain K*******
differential lock
P1: Clutch oil pressure pickup port
1. Proportional solenoid connector

2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Nameplate (*1)
HM400-2 51
Outline
ECMV for lockup clutch ECMV for differential lock clutch
• This valve acts to set the lockup clutch oil pres- • For each ECMV, 1 proportional solenoid is in-
sure to the set pressure, and also to switch the stalled.
lockup clutch. The proportional solenoid generates thrust
It forms a modulation wave pattern, so the shown below according to the command current
lockup clutch is engaged smoothly to reduce from the controller.
the shock when shifting gear. In addition, it pre- The thrust generated by the proportional sole-
vents generation of peak torque in the power noid is applied to the pressure control valve
train. As a result, it provides a comfortable ride spool to generate oil pressure as shown in the
for the operator and greatly increases the dura- figure below. Accordingly, the thrust is changed
bility of the power train. by controlling the command current to operate
the pressure control valve to control the flow
Torque converter travel o direct travel and pressure of the oil.
Current - propulsion force characteristics of

proportional solenoid
When shifting gear (direct travel)
Propulsion force - hydraulic pressure character-

istics of proportional solenoid
52 HM400-2
Operation
Clutch “disengaged“ (released) When clutch is “engaged“ (fixed)
• Under the condition where any current is not • If current is applied to proportional solenoid (1),
sent to the proportional solenoid (1), pressure the oil pressure force balanced with the solenoid
control valve (3) drains the oil from clutch port force is applied to chamber (B) and pushes pres-
(A) through drain port (T). sure control valve (3) to the left. As a result, the
circuit between pump port (P) and clutch port (A)
opens, and oil starts to fill the clutch.
• When the clutch is filled with oil, the propulsion
force of the solenoid, the propulsion force gener-
ated by the oil pressure in the clutch port, and
the tension of pressure control valve spring (2)
come into balance, and the pressure is adjusted.
HM400-2 53
Main relief, torque converter relief valve 1
Unit: mm

Clearance between the main size Shaft Hole clearance limit
1
relief valve and the valve body
-0.035 +0.013 0.035 –
28 0.078
-0.045 0 0.058
Clearance between the torque
-0.035 +0.013 0.035 –
2 converter 22 0.078
-0.045 0 0.058
relief valve and the valve body
Standard size Repair limit
Replace
Installed Installed Installed
Main relief valve spring Free length Free length
3 length load load
(outside)
275 N 261 N
108 79.5 104.8
{28.0 kg} {26.6 kg}
Main relief valve spring 326 N 309 N
4 108 79.5 104.8
(inside) {33.2 kg} {31.5 kg}
Torque converter relief valve 173 N 164 N
5 50 41 48.5
spring {17.6 kg} {16.7 kg}
6. Body A: Drain (Torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief oil pressure pickup port
54 HM400-2
Outline Operation of main relief valve
Torque converter relief valve

The torque converter relief valve maintains the oil
pressure in the torque converter inlet circuit always
below the set pressure in order to protect the torque
converter from abnormally high pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
Main relief valve

The main relief valve is keeping each oil pressure of
the transmission and the brake below the set
pressure.
Set pressure: 2.60 MPa {26.5 kg/cm2} • The oil from the hydraulic pump flows through
(Engine at rated rotation) the filter, port (C) of the relief valve, and orifice
(a) of main relief valve (1) to chamber (F).
Operation
Operation of torque converter relief valve
• When the oil pressure in the circuit exceeds the

set pressure, the oil in chamber (F) pushes pis-
ton (2), the reaction force of which moves spool
• The oil from the main relief valve flows through (1) to the left to open port (C) and port(E).
port (E) to the torque converter, and at the same Then the oil from the pump flows through port
time, also flows through orifice (b) of torque con- (E) into the torque converter.
verter relief valve (3) to chamber (G).
• When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber (G)
pushes piston (4), the reaction force of which
moves torque converter relief valve (3) to the
right to open port (E) and port (A).
Then the oil in port (E) is drained from port (A)
to the oil tank.
HM400-2 55

© 2007 KOMATSU
All Rights Reserved
56 HM400-2
SEN00519-02
HM400-2

HM400-2 2001 and up

Power train, Part 2
Drive shaft....................................................................................................................................................... 2
Axle ................................................................................................................................................................. 6
Differential ..................................................................................................................................................... 10
Limited slip differential .................................................................................................................................. 22
Final drive ..................................................................................................................................................... 26
HM400-2 1
Drive shaft 1
1. Drive shaft (right) 4. Center drive shaft

2. Front drive shaft 5. Rear drive shaft (front)
3. Drive shaft (left) 6. Rear drive shaft (rear)
k Precautions for tightening torque of spider 3. For the above reason, when "retightening",
mounting bolts "removing" or "installing", be sure to replace the
existing bolts with new bolts and tighten them to
1. There are 2 types (new and old types) of the the torque specified for them.
spider mounting bolts which have the same part a A new part No. is set for the new bolt. For
No. the new part No., see the parts book.
a Different tightening torques are specified for 3 * Spider mounting bolts (A, C, J):
the new bolt and old bolt. 107 – 127 Nm {10.9 – 13 kgm}
3 Shaft mounting bolts (B, D, K):
2. Since the new and old bolts cannot be distin- 98 – 123 Nm {10 – 12.5 kgm}
guished from each other by appearances, the 3 * Spider mounting bolts (E, G):
existing spider mounting bolts cannot be 215 – 255 Nm {21.9 – 26 kgm}
reused. 3 Shaft mounting bolts (F, H):
a The specified torque for the new bolt is 157 – 196 Nm {16 – 20 kgm}
lower than that for the old bolt. Accordingly, * Bolts of new tightening torque (New bolt
if the new bolt is tightened to the torque for values).
the old bolt, it may be broken during opera-
tion and the machine may not able to travel.
2 HM400-2
Front drive shaft
Left and right drive shaft
HM400-2 3
Center drive shaft
Rear drive shaft (front)
4 HM400-2
Rear drive shaft (rear)
Outline
• The power from the engine goes from the output
shaft through front drive shaft (2), the transmis-
sion, and the front axle, and is transmitted by left
and right drive shafts (1) and (3).
The rest of the power passes through center
drive shaft (4) and the oscillation hitch, and is
transmitted by rear drive shafts (5) and (6) to
the rear axles.
• The drive shaft does not simply act to transmit
the power. It also has the following purposes.
When articulating, or when there is impact from
the road surface during travel operations or
impact during operations, the position of the
engine, transmission, and axles changes.
To enable the power to be transmitted without
causing damage to any components by the
impact or change in position, the drive shaft has
a universal joint and slipping joint to enable it to
cope with any changes in the angle or length.
HM400-2 5
Axle 1
Front
1. Drive shaft
3. Brake
4. Final drive
6 HM400-2
Center
1. Center axle
3. Brake
4. Final drive
5. Oil filler port / level plug
6. Drain plug
HM400-2 7
Rear
1. Drain plug
2. Rear axle
3. Oil filler port / level plug
5. Brake
6. Final drive
8 HM400-2
HM400-2 9
Differential 1
Front
1. Bevel gear (No. of teeth: 41) 5. Pinion gear (No. of teeth: 14)
2. Bevel pinion (No. of teeth: 12) 6. Shaft
3. Differential case 7. Plate
4. Side gear (No. of teeth: 24) 8. Disc
10 HM400-2
Unit: mm

Wear of coupling oil seal con-
9 0
tact surface 95 94.9 Repair or
-0.087
replace
Wear of coupling oil seal con- 0
10 110 109.9
tact surface -0.087
Thickness of side gear thrust
11 4 ± 0.05 3.5
washer
Replace
12 Thickness of disc 3.5 ± 0.1 3.1
13 Thickness of plate 2.1 ± 0.1 1.9
Backlash between bevel gear 0.42 – 0.65
14 Adjust
and pinion (in circumferential direction at bevel gear outside diameter)
HM400-2 11
Center
1. Disc 5. Shaft
2. Plate 6. Side gear (No. of teeth: 24)
3. Pinion gear (No. of teeth: 14) 7. Bevel gear (No. of teeth: 41)
4. Differential case 8. Bevel pinion (No. of teeth: 12)
12 HM400-2
Unit: mm

Wear of coupling oil seal con- Repair or
9 0
tact surface 95 94.9 replace
-0.087
10 4 ± 0.05 3.5
washer
Replace
13 Adjust
HM400-2 13
Rear
1. Pinion gear (No. of teeth: 14)

2. Shaft
3. Differential case
4. Plate
5. Disc
6. Side gear (No. of teeth: 24)
7. Bevel gear (No. of teeth: 41)
8. Bevel pinion (No. of teeth: 12)
14 HM400-2
Unit: mm

9 0
-0.087
10 4 ± 0.05 3.5
washer
Replace
13 Adjust
HM400-2 15
(Machine with limited slip differential)

Front
1. Bevel gear (No. of teeth: 41) 6. Shaft

2. Bevel pinion (No. of teeth: 12) 7. Shaft
3. Limited slip differential 8. Disc
4. Side gear (No. of teeth: 24) 9. Plate
16 HM400-2
Unit: mm

Wear of coupling oil seal con-
10 0
tact surface 95 94.9 Repair or
-0.087
replace
Wear of coupling oil seal con- 0
11 110 109.9
tact surface -0.087
12 Adjust
HM400-2 17
Center
1. Bevel pinion (No. of teeth: 13) 5. Limited slip differential

2. Disc 6. Bevel gear (No. of teeth: 42)
3. Plate 7. Side gear (No. of teeth: 24)
4. Pinion gear (No. of teeth: 14) 8. Shaft
18 HM400-2
Unit: mm

9 0
-0.087
10 Adjust
HM400-2 19
Rear
1. Bevel pinion (No. of teeth: 12)

2. Plate
3. Disc
4. Bevel gear (No. of teeth: 41)
5. Shaft
6. Limited slip differential
8. Side gear (No. of teeth: 24)
20 HM400-2
Unit: mm

9 0
-0.087
10 Adjust
Operation When turning

• The power from the engine is transmitted • When the machine is turned, the speed that the
through the output shaft, front drive shaft, torque wheels turn on the left and right sides is differ-
converter, and transmission to each axle. ent, so pinion gear (6) and side gear (3) inside
• Inside the axle, the power is transmitted from the differential rotate according to the difference
pinion gear (5) to bevel gear (1), is converted in the turning speed on the left and right sides,
and sent at 90f, has its speed reduced, and is and transmit the power of differential case (2) to
transmitted through pinion gear (6) and side the left and right shafts.
gear (3) to the axle shaft.
• The power transmitted to the axle shaft has its
speed further reduced by the planetary gear
type final drive, and is transmitted to the wheels.
When differential lock is actuated

• If the load resistance on the wheel on one side
is lost (such as when the wheel is in mud), only
When traveling in a straight line
the wheel on the side where there is little load re-
• When the machine is traveling in a straight line,
sistance turns, and as a result, the power cannot
the speed that the wheels turn on the left and
be transmitted.
right sides is the same, so pinion gear (6) inside
the differential assembly does not turn, and the In such a case, it becomes impossible to travel,
power of differential case (2) is transmitted so differential lock (7) is actuated to stop the
equally through side gear (3) to the left and right rotation of pinion gear (4) and transmit the
shafts. power equally to left and right axle shafts (2).
HM400-2 21
Limited slip differential 1
1. Washer
2. Disc
3. Plate
4. Bevel gear
5. Pressure ring
6. Side gear
7. Pinion gear
8. Shaft
9. Case
10. Cover
11. Shaft
22 HM400-2
Unit: mm

1 Plate thickness 3.4
±0.03 3.3
3.5
+0.04
2 Disc thickness 3.6 3.55
–0.03
Clearance between disc and
3 0.2 – 0.75
plate (Total on both sides)
4 Replace
4 Washer thickness ±0.05 3.8
4.1
End play of side gear in axial
5 0.2 – 0.4
direction (Each side)
Backlash between case and
6 0 – 0.4
plate
Backlash between side gear
7 0.13 – 0.36
and disc
HM400-2 23
Operation of limited slip differential

The power transmitted from the transmission goes
from bevel gear (4) to case (9), pressure ring (5),
shaft (8), pinion gear (7), side gear (6), and is then
divided and sent to left and right shafts (11). A brake
mechanism consisting of disc (2) and plate (3) is as-
sembled at the rear face of side gear (6), and the
brake torque is generated in proportion to the torque
transmitted from pressure ring (5) to shaft (8).
In order for this brake torque to act to suppress the
rotation in relation to side gear (6) and case (9), it is
made difficult for left and right side gears (6) to rotate
mutually, and the action of the differential is sup-
pressed.
<Mechanism for generation of brake torque of

left and right side gears (6)>
Shaft (8) is supported by the cam surface cut into the
mating surfaces of left and right pressure rings (4).
The power (= torque) transmitted from pressure ring
(4) to shaft (8) is transmitted by the cam surface, but
force Fa to separate left and right pressure rings (4)
is generated in proportion to the torque transmitted
by the angle of this cam surface.
This separation load Fa acts as a brake on the rear
face of left and right side gears (6) and generates
brake torque.
<When travelling is straight line >

1. When there is no imbalance between drive
force of left and right wheels.
(The road surface condition (friction coeffident)
for the left and right wheels and the load on the
wheels are uniform.)
The power from the transmission is divided uni-
formly to the left and right by the limited slip dif-
ferential. Under these conditions, the limit for
wheel slip for the left and right wheels is the
same, so even if the power from the transmis-
sion exceeds the wheel slip limit, the wheels on
both sides slip and the differential is not actuat-
ed.
No load is applied to the brake at the rear sur-
face of the side gear.
24 HM400-2
2. When there is imbalance between drive force

of left and right wheels
(The road surface condition (friction coefficient)
for the left and right wheels and the load on the
wheels are not uniform and the wheel on one
side tends to slip more than the wheel on the
other side.)
• When wheel on one side is on soft ground sur-

face.
• The power from the transmission is divided uni-

formly to the left and right by the side gear.
However, if the divided drive force exceeds the
wheel slip limit on the side where the wheel is
slipping, a drive force equal to the excess is sent
through the brake at the rear face of the side
gear and the case to the brake on the opposite
side (side where wheel is locked), and is sup-
plied to the wheel on the side which is locked.
If this excess drive force becomes greater than
the braking force, the differential starts to be ac-
tuated.
Difference in wheel drive force for each type of differ-

ential when wheel on one side is slipping
Wheel drive force (taken as 1 for wheel

that is slipping)
Slipping Locked Total

wheel wheel (proportional)
Limited slip 1 2.64 3.64 (1.82)

differential
Normal 1 1 2 (1)
differential
On road surfaces where the wheel on one side is

likely to slip, the limited slip differential increases the
drive force 1.82 times that of the normal differential
supplied as standard.
<When turning>
The side gear built into the limited slip differential is
the same as the gear used on the normal differential,
so the difference in rotation of the inside and outside
wheels generated when turning can be generated
smoothly.
HM400-2 25
Final drive 1
Front
1. Axle shaft
2. Ring gear (No. of teeth: 67)
3. Planet gear (No. of teeth: 24)
4. Planet carrier
5. Sun gear (No. of teeth: 17)
6. Drain plug
7. Brake
26 HM400-2
Unit: mm
Backlash between planet gear

8 0.19 – 0.43
and sun gear
Replace
9 0.19 – 0.53
and ring gear
10 Curvature of drive shaft Repair limit: 0.7TIR Repair or replace

11 Thickness of spacer Replace
12 ± 0.1 11.5
Wear of outside diameter of
+0.040
12 portion of ring gear hab 180 180.0
+0.015
inserted into bearing
Correct
-0.030
13 portion of axle tube inserted 170 169.83
-0.055
into bearing

Clearance between shaft (out- size Shaft Hole clearance limit
14 Replace
side diameter) and bushing
0 +0.39 0.409 –
65 0.4
-0.019 +0.32 0.32
HM400-2 27
Center, rear
1. Axle shaft 5. Sun gear (No. of teeth: 17)

2. Ring gear (No. of teeth: 67) 6. Drain plug
3. Planet gear (No. of teeth: 24) 7. Brake
4. Planet carrier
Unit: mm

8 0.19 – 0.43
and sun gear
Replace
9 0.19 – 0.53
and ring gear
10 Curvature of drive shaft Repair limit: 1.5TIR Repair or replace

11 Thickness of spacer Replace
26 ± 0.1 11.5
+0.040
12 portion of ring gear hab 180 180.0
+0.015
inserted into bearing
Correct
-0.030
13 portion of axle tube inserted 170 169.83
-0.055
into bearing
28 HM400-2
Function
• The final drive uses a planetary gear mechanism
to reduce the speed in order to give a large drive
force, and transmits this drive force to the tires.
Operation
• The power from the differential passing through
axle shaft (1) is transmitted to sun gear (5) and
then goes to planet gear (3).
The planet gear rotates on the inside of fixed
ring gear (2) and transmits the reduced speed
to planetary carrier (4). This power is then
transmitted to the wheels that are installed to
the planetary carrier.
HM400-2 29

© 2008 KOMATSU
All Rights Reserved
30 HM400-2
SEN00520-01
HM400-2

HM400-2 2001 and up

Steering system
Steering column .............................................................................................................................................. 2
HM400-2 1
Steering column 1
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Join shaft
6. Steering valve
2 HM400-2
HM400-2 3

© 2007 KOMATSU
All Rights Reserved
4 HM400-2
SEN00521-02
HM400-2

HM400-2 2001 and up

Brake system
Brake piping .................................................................................................................................................... 2
Brake valve ..................................................................................................................................................... 4
Accumulator charge valve............................................................................................................................... 7
Accumulator ...................................................................................................................................................11
Slack adjuster ............................................................................................................................................... 12
Brake............................................................................................................................................................. 14
Proportional reducing valve .......................................................................................................................... 19
Brake system tank ........................................................................................................................................ 20
Parking brake................................................................................................................................................ 22
Parking brake solenoid valve ........................................................................................................................ 26
HM400-2 1
Brake piping 1
2 HM400-2
1. Accumulator charge valve

2. Shuttle valve
3. Slack adjuster
4. Brake filter
5. Brake valve
6. Brake system tank
7. Accumulator (for front)
8. Accumulator (for rear)
9. Accumulator (for parking)
10. Proportional reducing valve
11. Parking brake solenoid valve
HM400-2 3
Brake valve 1
1. Pilot piston A: To center brake

2. Rod B: To front brake
3. Lower cylinder T: To brake system tank
4. Spool PA: From center, rear accumulator
5. Upper cylinder PB: From front accumulator
6. Spool
4 HM400-2
Operation Applying brake when upper valve fails

• Even if there is leakage of oil in the upper piping,
Upper portion spool (5) is moved down mechanically when
• When brake pedal (1) is depressed, the operat- pedal (1) is depressed, and the lower portion is
ing force is transmitted to spool (3) through rod actuated normally.
(2) and spring (4). When spool (3) goes down, The upper portion brake is not actuated.
drain port a is closed, and the oil from the pump
and accumulator flows from port (PA) to port (A) Applying brake when lower valve fails
and actuates the center brake cylinder. • Even if there is leakage of oil in the lower piping,
the upper portion is actuated normally.
Lower portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port (b) is closed, and
the oil from the pump and accumulator flows
from port (PB) to port (B) and actuates the front
brake cylinders.
When actuation is balanced

Upper portion
• When oil fills the center brake cylinders and the
pressure between port (PA) and port (A) be-
comes high, the oil entering port (H) from orifice
(e) of spool (3) pushes against spring (4). It
pushes up spool (3) and shuts off the circuit be-
tween port (PA) and port (A). When this hap-
pens, drain port (a) stays closed, so the oil
entering the brake cylinder is held and the brake
remains applied.
HM400-2 5
Lower portion Brake released

• When spool (3) in the upper portion moves up
and the circuit between port (PA) and port (A) is Upper portion
shut off, oil also fills the front brake cylinder at • When pedal (1) is released and the operating
the same time, so the pressure in the circuit be- force is removed from the top of the spool, the
tween port (PB) and port (B) rises. The oil enter- back pressure from the brake cylinder and the
ing port (J) from orifice (f) of spool (5) pushes up force of the spool return spring move spool (3)
spool (5) by the same amount that spool (3) up. Drain port (a) is opened and the oil from the
moves, and shuts off port (PB) and port (B). brake cylinder flows to the brake system tank re-
Drain port (b) is closed, so the oil entering the turn circuit to release the center and rear brakes.
brake cylinder is held, and the brake is applied.
• The pressure in the space in the upper portion is
balanced with the operating force of the pedal, Lower portion
and the pressure in the space in the lower por- • When the pedal is released, spool (3) in the up-
tion is balanced with the pressure in the space in per portion moves up. At the same time, the
the upper portion. When spools (3) and (5) move back pressure from the brake cylinder and the
to the end of their stroke, the circuits between force of the spool return spring move spool (5)
ports (PA) and (A) and between ports (PB) and up. Drain port (b) is opened and the oil from the
(B) are fully opened, so the pressure in the brake cylinder flows to the brake system tank re-
space in the upper and lower portions and the turn circuit to release the front brake.
pressure in the left and right brake cylinders is
the same as the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
6 HM400-2
Accumulator charge valve 1
ACC: To accumulator Function

P: From hydraulic pump • The accumulator charge valve is actuated to
PP: To accumulator (pirot pressure) maintain the oil pressure from the pump at the
T: To brake tank specified pressure and to store it in the accumu-
lator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load of the pump.
HM400-2 7
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
8 HM400-2
Operation 2. When oil supplied to accumulator

1) Cut-in condition
1. When no oil is being supplied to accumulator • When the pressure at port B is lower than the set
(cut-out condition) pressure of the relief valve (R1), piston (8) is
• The pressure at port (B) is higher than the set pushed back down by spring (5).
pressure of the relief valve (R1), so piston (8) is Valve seat (7) and poppet (6) are brought into
forcibly pushed up by the oil pressure at port (B). tight contact, and port (C) and port (T) are shut
Poppet (6) is opened, so port (C) and port (T) are off.
short circuited. • The spring chamber at the right end of spool (15)
• The spring chamber at the right end of spool (15) is also shut off from port (T), so the pressure ris-
is connected to port (C) of the relief valve (R1), es, and the pressure at port (P) also rises in the
so the pressure becomes the oil tank pressure. same way.
The oil from the pump enters port (P), pushes • When the pressure at port (P) goes above the
spool (15) to the right at a low pressure equiva- pressure at port (B) (accumulator pressure), the
lent to the load on spring (14). supply of oil to the accumulator starts immedi-
It also passes through orifices (17), (18) and ately. In this case, it is decided by the size (area)
(16), and flows to the oil tank. of orifice (17) and the pressure difference
(equivalent to the load on spring (14)) generated
on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed.
HM400-2 9
2) When cut-out pressure is reached 3. Main relief valve (R3)

• When the pressure at port (B) (accumulator • If the pressure at port (P) (pump pressure) goes
pressure) reaches the set pressure of the relief above the set pressure of the relief valve (R3),
valve (R1), poppet (6) separates from valve seat the oil from the pump pushes spring (3). Ball (11)
(7), so an oil flow is generated and the circuit is is pushed up and the oil flows to the brake oil
relieved. tank circuit, so this set the maximum pressure in
• When the circuit is relieved, a pressure differ- the brake circuit and protects the circuit.
ence is generated above and below piston (8),
so piston (8) moves up, poppet (6) is forcibly
opened, and port (C) and port (T) are short cir-
cuited.
• The spring chamber at the right end of spool (15)
is connected to port (C) of the relief valve (R1),
so the pressure becomes the brake oil tank
pressure.
• The pressure at port (P) drops in the same way
to a pressure equivalent to the load on spring
(14), so the supply of oil to port (B) is stopped.
10 HM400-2
Accumulator 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
• The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydraulic
pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Gas used: Nitrogen gas
Gas capacity: 4,000 cc
Charging pressure: 4.4 ± 0.15MPa
{45 ± 1.5kg/cm2} (at 20 °C ± 5 °C)
HM400-2 11
Slack adjuster 1
1. Breather
2. Cylinder
3. Check valve
4. Spring
5. Piston
A: Inlet port
B: Outlet port
Unit: mm

size Shaft Hole clearance limit
Clearance Front
6 between body and 55 -0.030 +0.074 0.030 – 0.25
piston -0.076 0 0.150
Center 55 -0.030 +0.074 0.030 – 0.25

-0.076 0 0.150
Standard size Repair limit Replace
Free Installed Installed Free Installed

Front length length load length load
7 Slack adjuster
spring 230 88 118 N – –
{12 kg}
39.2 N
Center 198 60 {4.0 kg} – –
12 HM400-2
Specifications • If the brake pedal is depressed further, and the

Piston actuation oil pressure: oil pressure discharged from the brake valve
9.8 +9.8
+0 kPa {0.1 +0.1
+0 kg/cm2} goes above to set pressure, check valve (3)
Check valve cracking pressure: opens and the pressure is applied to port (C) to
1.74 ± 0.05 MPa {17.8 ± 0.5 kg/cm2} act as the braking force.
Check valve closing pressure: Therefore, when the brake is applied, the time
1.09 ± 0.05 MPa {11.1 ± 0.5 kg/cm2} lag is a fixed valve.
Function
• The slack adjuster is installed in the brake oil line
from the brake valve to the brake piston. It acts
to keep a constant time lag when the brake is
operated.
Operation
1. When brake pedal is depressed

• Before the brake is depressed, piston (4) is re-
turned by the distance of stroke (S) (full stroke).
When the brake pedal is depressed, the oil dis-
charged from the brake valve flows from port (P) 2. When brake pedal is released
of the slack adjuster and is divided to left and • When the brake is released, piston (4) returns
right cylinders (2), where it moves piston (4) by because of lowering of the brake oil pressure by
stroke (S) to the left and right. an amount equivalant to the oil for stroke (S),
and the brake is released again.
In other words, return stroke T of brake piston
(7) is determined by the amount of oil for stroke
(S) of the slack adjuster. The time lag of the
brake is always kept constant regardless of the
wear of the brake disc.
• As a result, brake piston (7) moves by an

amount equal to stroke (S). When this happens,
the relationship between the brake piston and
disc is simply that the clearance becomes 0. No
braking force is generated.
HM400-2 13
Brake 1
Front
1. Stud bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
14 HM400-2
Unit: mm
Backlash between outer gear Standard size Repair limit

1
and plate 0.52 – 0.90 1.5
Backlash between hub gear
2 0.52 – 0.90 1.5
and plate
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6
Replace
5 Thickness of damper 6.9 5.1
Standard warping Repair limit
6 Warping of disc friction surface
Max 0.45 0.7
Warping of plate and damper
7 Max 0.50 0.7
friction surface
Assemble thickness of plate, Standard warping Repair limit

8
disc and damper 56.4 51.4
HM400-2 15
Center, rear
1. Bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
16 HM400-2
Unit: mm
Backlash between outer gear Standard size Repair limit

1
and plate 0.52 – 0.90 1.5
Backlash between hub gear
2 0.52 – 0.90 1.5
and plate
3 Thickness of plate
2.4 2.15
4 Thickness of disc 5.1 4.6
Replace
5 Thickness of damper 6.9 5.1
Standard warping Repair limit
6 Warping of disc friction surface
Max 0.45 0.7
Warping of plate and damper
7 Max 0.50 0.7
friction surface
Assemble thickness of plate, Standard warping Repair limit

8
disc and damper 56.4 51.4
HM400-2 17
Function
• There are wet-type multiple disc brakes installed
to all of the six wheels.
Operations
• When the brake pedal is depressed, pressure oil
from the brake valve moves brake piston (3) to
the right in the direction of the arrow. This press-
es disc (7) and plate (6) together and generates
friction between the disc and plate. The wheel is
rotating together with the disc, so this friction re-
duces the travel speed and stops the machine.
• When the brake pedal is released, the pressure

at the back face of brake piston (3) is released,
so the piston is moved to the left in the direction
of the arrow by the internal pressure, and this re-
leases the brake.
18 HM400-2
Proportional reducing valve 1
1. Filter Function
2. Connector • The proportional reducing valve is a valve used
3. Solenoid assembly for retarder control. It is installed between the
brake valve and the system tank in the brake cir-
A: To slack adjuster cuit.
P: From accumulator It varies the discharge pressure of the pressure
T: To brake system tank oil in accordance with the turning angle of the
retarder control lever, so the retarder control
can be carried out as desired.
HM400-2 19
Brake system tank 1
1. Inlet tube
2. Outlet tube
3. Oil gauge
4. Valve
A: From accumulator charge valve and brake valve

B: To transmission
C: To hydraulic pump
20 HM400-2
HM400-2 21
Parking brake 1
1. Spring cylinder Function

2. Parking brake disc • The parking brake is a disc type and is installed
3. Parking brake caliper to the oscillation hitch.
• It is actuated mechanically by the force of the
spring inside the spring cylinder and is released
by hydraulic pressure.
• The parking brake caliper is fixed to the oscilla-
tion hitch.
The disc is installed to the oscillation hitch shaft
output coupling and rotates together with the
coupling.
22 HM400-2
Unit: mm
Standard backlash Repair limit Repair or

4 Face runout of disc
0.4 0.8 replace
Rebuid
(Thickness of
Min. 20
5 Thickness of disc 25 disc must not be
under 20 mm)
Max. 20
Thickness of pad (including Replace
6 21.5 11.5
thickness of plate)
Standard dimen- Standard Allowable
Tolerance
sion of blade clearance clearance
0
22.3
-0.3
Clearance between blade and Correct or
7 Standard
brake assembly Tolerance replace
dimension of 1.0 ± 0.4 1.5
brake assembly
+0.4
22.3
-0.1
HM400-2 23
Parking brake caliper
1. Adjuster Outline
2. Piston • A piston guide is installed to caliper (5). Piston
3. Piston shaft (2) and piston shaft (3) are inserted, and the ro-
4. Pad tation of piston shaft (3) moves piston (2) in the
5. Caliper axial direction to bring pad (4) into tight contact.
• The adjuster (1) is joined by a spline to the spline
side of piston shaft (3).
Pad (4) is inserted together with caliper (5) into
the caliper mounting plate and is held in posi-
tion.
24 HM400-2
Spring cylinder
1. Outer spring Outline

2. Inner spring • The oil pressure from the parking brake solenoid
3. Piston valve pushes the spring and releases the park-
4. Cylinder ing brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by springs (1) and (2), so the machine
is prevented from moving.
HM400-2 25
Parking brake solenoid valve 1
1. Solenoid valve assembly Function

2. Relief valve • The parking brake solenoid valve is installed be-
3. Block tween the secondary brake valve and parking
brake.
A: Outlet port If the parking brake switch is set to "Travel", the
P: Inlet port solenoid valve is energized and the brake oil
T: Drain port pressure is sent to the parking brake spring cyl-
inder to release the parking brake.
If the parking brake switch is set to "Park", the
solenoid valve is de-energized and the brake oil
pressure is relieved from the parking brake
spring cylinder to operate the parking brake.
26 HM400-2
HM400-2 27

© 2009 KOMATSU
All Rights Reserved
28 HM400-2
SEN00522-02
HM400-2

HM400-2 2001 and up

Undercarriage and frame
Suspension ..................................................................................................................................................... 2
Suspension cylinder........................................................................................................................................ 7
Oscillation hitch............................................................................................................................................... 9
HM400-2 1
Suspension 1
Front
2 HM400-2
1. Front suspension cylinder

2. Arm
3. Lateral rod
4. Dust cover
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
5
bushing
60 -0.030 +0.046 0.030 – 0.3 Replace
-0.076 0 0.122
Clearance between pin and -0.030 +0.046 0.030 –
6 bushing 60 -0.076 0 0.122 0.3
HM400-2 3
Rear
4 HM400-2
1. Arm
2. Equalizer bar
3. Lateral rod (center)
4. Spring
5. Rear suspension
6. Lateral rod (rear)
HM400-2 5
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
7
bushing
60 -0.030 +0.046 0.030 – 0.3
-0.076 0 0.122 Replace
Clearance between pin and -0.030 +0.046 0.030 –
8 bushing 60 -0.076 0 0.122 0.3
9 Clearance between pin and 60 -0.030 +0.046 0.030 – 0.3

bushing -0.076 0 0.122
Outline 2. Center, rear suspension

• The suspension supports the weight of the ma- The center axle and rear axle are both fixed to arms.
chine. It also reduces any impact caused by un- The center axle is joined to the equalizer bar through
evenness in the road surface and provides a a spring, and the rear axle is joined through the rear
comfortable ride for the operator. By ensuring suspension cylinder. The arm and equalizer bar os-
that all the tires are always in contact with the cillate in accordance with the condition
road surface, it maintains the stability of the ma- of the road surface to keep the wheels in contact with
chine, and also fulfills the operating perfor- the road surface.
mance by ensuring that the machine can carry The main frame and arm are connected by a lateral
out acceleration, braking, and turning. rod and receive the lateral load.
• The suspension cylinders reducing the impact
from the road surface are a hydropneumatic
type. The inside of the suspension cylinder is
charged (sealed) with oil and nitrogen gas. In
this way, the compression and expansion of the
nitrogen gas and oil act as a spring and shock
absorber, and is used to absorb the load from
the road surface.
Function
1. Front suspension
The front suspension cylinder has the function of a
shock absorber and spring. It is joined to the arm
and main frame by a spherical bearing, and the arm
oscillates according to the extension and retraction
of the front suspension cylinder.
The main frame and arm are joined by a lateral rod
and receive the lateral load.
6 HM400-2
Suspension cylinder 1
1. Oil level valve

2. Feed valve
3. Retainer
4. Rod
5. Flange
6. Cylinder
HM400-2 7
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
7
and bushing
140 -0.043 +0.277 0.104 – 0.4
-0.106 +0.061 0.383 Replace
Clearance between piston rod -0.043 +0.277 0.104 –
8 and bushing 140 -0.106 +0.061 0.383 0.7
9 Clearance between cylinder 180 0 +0.010 0 – 0.22 0.8

and wear ring -0.21 0
Structure and operation

The suspension cylinder has the function of both a
shock absorber and spring.
When a fixed amount of oil is sent from oil chamber
(1) through orifices (4) and (5) to cavity (3), the oil is
throttled by the orifices and a shock-absorbing effect
is obtained.
1. Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (2) is compressed, the oil in chamber
(1) is sent through both orifices (4) and (5) to
cavity (3), and cavity (3) is filled more quickly
than when extending.
2. Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(2).
As a result, the amount of oil in cavity (3) is
reduced, and pressure is applied to the oil
remaining in cavity (3).
This pressurized oil closes orifice (4) with check a This drawing shows rear suspension cylinder.
ball (6), and is sent to chamber (1) through only
orifice (5), so the flow of oil passing through the 1. Oil chamber
orifice is controlled so that it is less than during 2. Nitrogen gas chamber
retraction. 3. Cavity
In this way, the amount of oil returning to cham- 4. Orifice
ber (1) is restricted to provide a shock absorb- 5. Orifice
ing effect. 6. Check ball
8 HM400-2
Oscillation hitch 1
1. Steering cylinder 7. Hitch frame

2. Front frame 8. Disc
3. Center drive shaft 9. Coupling
4. Rear frame 10. Shaft
5. Rear drive shaft (front) 11. Coupling
6. Pin 12. Pin
HM400-2 9
10 HM400-2
Unit: mm

1 Standard shim thickness size Shaft Hole clearance limit
2
2 Standard shim thickness 1.5
Clearance between bushing -0.036 +0.054 0.036 –
3 115 -0.090 0 0.144 –
and front frame
Clearance between shaft and -0.036 +0.054 0.036 –
4 bushing 85 -0.058 0 0.112 –
5 Clearance between shaft and 85 -0.036 0 0.016 – –

bearing -0.058 -0.020 0.058
6 Clearance between shaft and 85 -0.036 +0.054 0.036 – –

bushing -0.058 0 0.112
Clearance between front frame -0.036 +0.054 0.036 –
7 and shaft 85 -0.058 0 0.112 –
8 Standard shim thickness 2
9 Clearance between front frame 85 -0.036 +0.054 0.036 – –

and pin -0.058 0 0.112 Replace
Clearance between pin and -0.036 0 0.016 –
10 bearing 85 -0.058 -0.020 0.058 –
Clearance between front frame -0.036 +0.054 0.036 –

11 and pin 85 -0.058 0 0.112 –
12 Clearance between hitch frame 150 0 0 -0.040 – –

and bearing -0.018 -0.040 0.018
Clearance between hitch frame 0 0 -0.040 –
13 and bearing 340 -0.057 -0.040 0.057 –
Clearance between rear frame 0 -0.017 -0.080 –

14 and bearing 460 -0.045 -0.080 0.028 –
15 Clearance between rear frame 435 -0.020 +0.063 0.020 – –

and bearing -0.083 0 0.146
Clearance between rear frame 0 -0.017 -0.080 –
16 and bearing 420 -0.045 -0.080 0.028 –
Clearance between bearing -0.056 0 0.021 –

17 and hitch frame 300 -0.108 -0.035 0.108 –
18 Standard shim thickness 3
Outline
• The front frame and the rear frame are connect- • In addition, the output from the transmission is
ed by the oscillation hitch. transmitted from center drive shaft (3) to cou-
• Front frame (2) is connected with bearings and pling (9). It is then transmitted from coupling
pins (6) and (12); rear frame (4) is connected (11) through the rear drive shaft (5) to the rear
with a spacer, retainer, and bearing. This makes axle.
it possible for the front and rear frames to articu-
late and oscillate.
HM400-2 11

© 2009 KOMATSU
All Rights Reserved
12 HM400-2
SEN00523-02
HM400-2

HM400-2 2001 and up

Hydraulic system
Steering, hoist oil pressure piping diagram ..................................................................................................... 2
Dump body control.......................................................................................................................................... 3
Hydraulic tank and filter .................................................................................................................................. 4
Flow amp valve ............................................................................................................................................... 5
Steering valve ................................................................................................................................................. 8
Steering cylinder ........................................................................................................................................... 12
Hoist valve .................................................................................................................................................... 14
Dump control valve (EPC valve) ................................................................................................................... 20
Pilot check valve ........................................................................................................................................... 24
Hoist cylinder ................................................................................................................................................ 25
Hydraulic pump ............................................................................................................................................. 26
HM400-2 1
Steering, hoist oil pressure piping diagram 1
1. Steering, hoist control pump

(SDR(30)100+100+SB(1)8)
2. Steering cylinder
3. Hydraulic tank
4. Flow amp valve
5. Steering valve
6. Check valve
7. Hoist valve
8. Hoist cylinder
9. Line strainer
2 HM400-2
Dump body control 1
1. Dump control lever Function

2. EPC valve • This control is carried out by the body position
3. Hoist valve sensors. The body position sensor senses the
4. Steering, hoist control pump position of the dump body and the retarder con-
(SDR(30)100+100+SB(1)8) troller controls it.
5. Body positioner sensor • The signal from the dump control lever is con-
trolled by the retarder controller and actuates the
EPC valve. The pilot pressure generated by the
EPC valve moves the spool of the hoist valve
and controls the hoist cylinder.
HM400-2 3
Hydraulic tank and filter 1
1. Hydraulic oil filter

2. Breather
3. Oil level gauge
4. Drain plug
5. Bypass valve
6. Element
7. Strainer
4 HM400-2
Flow amp valve 1
1. Valve CL: To steering cylinder Outline

2. Relief Valve L: To steering valve • The flow amp valve consists of the directional
3. Orifice P: To steering valve valve, amplifying stage, priority valve, relief
4. Spring PP: From steering valve valve, pressure control valve, and suction valve.
5. Pin HP: From hydraulic pump • It amplifies the oil flow sent from ports (L) and
6. Valve LS: From steering valve (R) of the steering unit by the specified ratio.
7. Valve HT: From hoist valve The amplified oil then goes from ports (CL) and
8. Plug T: To steering valve (CR) of the flow amp valve and flows to the
9. Valve EF: To hoist valve steering cylinder.
10. Spool R: From steering valve The amplified oil flow is proportional to the
11. Valve body CR:To steering cylinder amount the steering wheel is turned.
12. Stopper
HM400-2 5
Operation
Operation
1. At neutral
• Port (P) of steering unit (7) is closed and the flow • For priority valve (2) also, the oil is drained from
amp valve is closed at chamber M of pressure relief valve (1).
control valve (3). Before starting, priority valve (2) is pushed
• Ports (L), (R), and (T) of steering unit (7) are strongly to the left by the spring, so in reality,
connected to each other, so the oil passes port (EF) of the flow amp valve is almost closed.
through port (T) of the flow amp valve and is • At the same time as the engine starts, oil flows
drained to the hydraulic tank. to port (HP) of the flow amp valve and then flows
By connecting in this way, directional valve (6) to port (P) of steering unit (7). At the same time,
is always held at the neutral position by the the pilot pressure that is connected to port (PP)
springs on both sides. For this reason, at the suddenly rises. As a result of balancing with
neutral position, the reaction or impact from the the spring and moving to the right, port (EF)
steering cylinder is not transmitted to steering opens and the oil flows to the hoist piping.
unit (7).
6 HM400-2
2. When turning
• When steering unit (7) is actuated, the oil sent • The oil at the steering cylinder head end goes
from port (P) of priority valve (2) passes through out from suction valve (5). It then goes from port
ports (P) and (L) of steering unit (7) and enters (CR) of directional valve (6) through check valve
port (L) of directional valve (6). (4) and is drained to the hydraulic tank from port
At the same time, oil from priority valve (2) also (HT) of the flow amp valve.
enters chamber (M) of pressure control valve • If there are rocks on the road or the the road sur-
(3). face is uneven, and any abnormal external force
• When the oil entering directional valve (6) rises is applied to the tires and steering cylinder, relief
to a pressure greater than the force of the valves (8) and (9) of suction valve (5) open at a
spring, it pushes the spool to the right, and en- pressure of 29.1 MPa {285.5 kg/cm2}, so the oil
ters chamber (C) of pressure control valve (3). passes through directional valve (6) and is
When it rises to a pressure greater than the drained to the hydraulic tank.
force of the spring in chamber (C) also, it push-
es the spool to the left.
• The oil that is already in chamber (M) of pres-
sure control valve (3) enters chamber (N) when
the spool is pushed to the left by the action of
steering unit (7). It then flows from port (P), goes
out from port (CL) of directional valve (6), and
flows from suction valve (5) to the bottom end of
the steering cylinder.
HM400-2 7
Steering valve 1
1. Cover L: To flow amp valve

2. Drive shaft LS: To flow amp valve
3. Valve body P: From flow amp valve
4. Center pin R: To flow amp valve
5. Bearing T: To flow amp valve
6. Spool
7. Centering spring
8. Sleeve
9. Stator
10. Rotor
11. Lower cover
8 HM400-2
Outline Structure
• The orbit-roll valve is connected directly to the • Spool (9) is connected to the drive shaft of the
steering wheel shaft. If the steering wheel is op- steering wheel, and is connected to sleeve (8)
erated, the orbit-roll valve operates the steering by center pin (7) (this is not touching the spool
valve by using the oil from the PPC pump as the when the steering wheel is at the neutral posi-
pilot pressure. Then, the oil from the steering tion) and centering spring (2).
pump is sent to the right or left steering cylinder • Drive shaft (3) is meshed at the top with center
through the steering valve to change the travel pin (7) and forms one unit with sleeve (8). The
direction of the machine. bottom is meshed with the spline of rotor (5) of
• The orbit-roll valve, broadly speaking, consists the Gerotor set.
of the following components: rotary type spool • Valve body (4) has five ports. These are con-
(9) and sleeve (8), which have the function of se- nected to the pump circuit, tank circuit, steering
lecting the direction, and the Girotor set (a com- cylinder head end, bottom end, and flow amp
bination of rotor (5) and stator (10)), which acts valve pilot end. In addition, the port at the pump
as hydraulic motor during normal steering oper- end and the port at the tank end are connected
ations, and as a hand pump (in fact, the operat- by the check valve inside the body. If there is
ing force of the steering wheel is too high, so it any failure in the pump or engine, this check
cannot be operated) when the steering pump or valve acts to suck in oil directly from the tank.
engine have failed and the supply of oil is
stopped.
HM400-2 9
Connection between hand pump and sleeve
• The diagrams above show the connections with

the sleeve ports used to connect the suction and Suctiion /
discharge port
discharged ports of the Girotor.
• If the steering wheel has been turned to the
right, ports (a), (c), (e), (g), (i) and (k) are con-
nected by the vertical grooves in the spool to the
pump side. At the same time, ports (b), (d), (f),
(h), (j) and (l) are connected to the head end of
the left steering cylinder in the same way.
In the condition in diagram above left, ports (1),
(2) and (3) are the discharge ports of the Girotor
set. SBW00727
They are connected to ports (l), (b) and (d) so
the oil is sent to the cylinder.
Ports (5), (6) and (7) are connected and the oil • In this way, the ports of the Girotor acting as de-
flows in from the pump. livery ports are connected to ports which are
If the steering wheel is turned 90°, the condition connected to the end of the steering cylinder.
changes to the condition shown in diagram The ports acting as suction ports are connected
above right. In this case, ports (1), (2) and (3) to the pump circuit.
are the suction ports, and are connected to • Adjusting delivery in accordance with angle of
ports (i), (k) and (c). Ports (5), (6) and (7) are steering wheel:
discharge ports, and are connected to ports (d), For every 1/7 turn of the steering wheel, the
(f) and (h). inner teeth of the Girotor gear advance one
position so the oil flow from the pump is
adjusted by this movement. In this way, the oil
delivered from the pump is directly proportional
to the amount the steering wheel is turned.
10 HM400-2
Function of center spring

• Centering spring (2) consists of four layers of
leaf springs crossed to form an X shape.
The springs are assembled in spool (9) and
sleeve (8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle
variation (a) arises between the spool and the
sleeve.
Because of this, the ports in the spool and
sleeve are connected and oil is sent to the cylin-
der. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no
more oil is sent to the cylinder and the oil pres-
sure rises.
To prevent this, when the turning of the steering
wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the difference in angle of rotation (angle vari-
ation (a) of the sleeve and spool, so the steer-
ing wheel returns to the NEUTRAL position.
HM400-2 11
Steering cylinder 1
Unit: mm

Clearance between piston rod size Shaft Hole clearance limit
1
and bushing
-0.030 +0.271 0.105 –
70 0.475
-0.104 +0.075 0.375
Clearance between piston rod 0 +0.174 0.100 –
2 65 1.0
support shaft and bushing -0.074 +0.100 0.248
Replace
Clearance between cylinder
0 +0.174 0.100 –
3 bottom support shaft and 65 1.0
-0.074 +0.100 0.248
bushing
4 Cylinder bore +0.15
120 –
0
12 HM400-2
HM400-2 13
Hoist valve 1
a ADT: Set pressure is increased or decreased by 19.6 MPa {200 kg/cm2} per turn.
14 HM400-2
A: To hoist cylinder head

B: To hoist cylinder bottom
P: From steering control valve
PA: From EPC valve (LOWER, FLOAT)
PB: From EPC valve (RAISE)
T: To tank
T2: To tank
1. Valve body
2. Hoist spool
3. Check valve
4. Housing
5. Relief valve
Unit: mm

Free length
Installed Installed Free Installed
x Outside
6 Spool return spring length load length load
diameter
308 N 246 N
63.4 x 61 61 –
{31.4 kg} {25.1 kg}
340 N 273 N
7 Spool return spring 47 x 36 45 –
{34.7 kg} {27.8 kg} If damaged or
deformed,
308 N 246 N replace spring.
8 Spool return spring 47.51 x 41 45.2 –
{31.4 kg} {25.1 kg}
1,370 N 1,100 N
9 Spool return spring 87.63 x 52 60 –
{140 kg} {112 kg}
823 N 658 N
10 Spool return spring 97.8 x 35 86 –
{83.9 kg} {67.1 kg}
12.7 N 10.2 N
11 Check valve return spring 84.7 x 26.6 47.5 –
{1.3 kg} {1.04 kg}
HM400-2 15
Operation
1. When hoist valve is in "HOLD" position
• The pressurized oil from the steering control • Since the port to the hoist cylinder is blocked on
valve flows in chamber (C). Since the passage both bottom side and head side, the hoist cylin-
to the hoist cylinder is blocked by hoist spool (2), der is held in the current position.
the pressurized oil flows through chamber (D) to
the tank.
16 HM400-2
2. When hoist valve is in "RAISE" position
• If the dump control lever in the cab is set in the • The pressurized oil returning from the head side
"RAISE" position, the pressurized oil from the flows through chambers (B) and (D) to the tank.
EPC valve moves hoist spool (2) to the left.
• Accordingly, the pressurized oil flows through
chamber (C), opens check valve (3), and enters
chamber (A).
• The pressurized oil flows through chamber (A) to
the bottom side of the hoist cylinder to extend
the hoist cylinder and raise the body.
HM400-2 17
3. When hoist valve is in "FLOAT" position
• If the dump control lever in the cab is set in the • The pressurized oil from the steering control
"FLOAT" position, the pressurized oil from the valve flows through chambers (C) and (B) to the
EPC valve moves hoist spool (2) to the right. hoist cylinder. A part of it flows through cham-
Then, chamber (C) is connected to chamber (D), bers (C) and (D) to the steering oil cooler, too.
and chambers (B) and (H) are connected to • Since the bottom side and head side of the hoist
chamber (D). cylinder are connected by the hoist valve, the
hoist cylinder is free.
18 HM400-2
4. When hoist valve is in "LOWER" position
• If the dump control lever in the cab is moved from • The pressurized oil returning from the head side
the "FLOAT" position to the "LOWER" position, of the hoist cylinder flows through chamber (A)
the pressurized oil from the EPC valve moves to chamber (H).
hoist spool (2) to the right further from the • When the dump body is lowered, the output
"FLOAT" position. Accordingly, the pressurized pressure of the EPC valve rises and becomes
oil flows through chamber (C), opens check valve greater than the cracking pressure of the pilot
(3), and enters chamber (B). check valve. As a result, the return oil from
• The pressurized oil flows through chamber (B) to chamber (H) returns to the tank through two
the head side of the hoist cylinder to retract the lines: one from chamber (D) to the tank, and the
hoist cylinder and lower the body. other from chamber (E) to the tank.
HM400-2 19
Dump control valve (EPC valve) 1

Serial No.: 2001 – 2603
1. Manual operation button Function

2. Solenoid assembly (Solenoid a) • With the EPC valve, the oil from the hydraulic
3. Relief valve (R) pump is controlled by the retarder controller. It
4. Solenoid assembly (Solenoid b) is then sent to the spool of the hoist valve, and
switches the pilot pressure to control the hoist
A: To hoist valve (RAISE side) valve.
B: To hoist valve (LOWER side)
P1: From hydraulic pump
P2: Pick up port
T1: To hydraulic tank
20 HM400-2
HM400-2 21
Serial No.: 2604 and up
22 HM400-2
1. Manual operation button

2. Solenoid assembly (Solenoid a)
3. Relief valve (R)
4. Solenoid assembly (Solenoid b)
5. Strainer
A: To hoist valve (RAISE side)

B: To hoist valve (LOWER side)
P1: From hydraulic tank
P2: Pick up port
Function
• The EPC valve sends the oil from the hydraulic
pump to the hoist valve spool to change the
pilot pressure and control the hoist valve.
HM400-2 23
Pilot check valve 1
1. Body A: From hoist valve

2. Check valve B: To hydraulic tank
3. Retainer P.P: From EPC valve
4. Spring
5. Cover
Unit: mm

Free length Installed Installed Free Installed Replace spring
6 Spring x O.D. length load length load if damaged or
deformed
821.2 N 739 N
198.5 x 53 70 –
{83.7 kg} {75.4 kg}
24 HM400-2
Hoist cylinder 1
Unit: mm

Clearance between cylinder size Shaft Hole clearance limit
1
and bushing
-0.043 +0.277 0.104 –
140 0.720
-0.143 +0.061 0.420
Clearance between piston rod -0.036 +0.270 0.097 – Replace
2 90 0.693
and bushing -0.123 +0.061 0.393
Clearance between piston rod +0.004
3 60 – – 1.0
support pin and bearing -0.019
Clearance between cylinder +0.004
4 60 – – 1.0
support pin and bushing -0.019
HM400-2 25
Hydraulic pump 1
Steering, hoist control pump
SDR(30)100+100+SB(1)8
Unit: mm
SDR(30)-100
1 Side clearance 0.16 – 0.20 0.24
SDR(30)-100
SB(1)-8 0.10 – 0.15 0.19
Clearance between inside SDR(30)-100
diameter of plain bearing and 0.06 – 0.13 0.20
2 SDR(30)-100 Replace
outside of diameter of gear
shaft SB(1)-8 0.06 – 0.12 0.20
SDR(30)-100 0
3 Depth for knocking in pin 10
SDR(30)-100 -0.5 –
SB(1)-8 9.2 ±0.3
Delivery Standard
Rotating Delivery
pressure delivery
{MPa amount
Discharge amount (rpm) (l/min) –
– Oil: EO10-CD (kg/cm2)} (l/min)
Oil temperature: 45–55°C SDR(30)-100
20.6 231 213.4
SDR(30)-100 2,500
{210}
SB(1)-8 17.2 15.8
26 HM400-2
Emergency steering pump

SBL(1)21
Unit: mm

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside
2 0.060 – 0.119 0.20
outside of diameter of gear Replace
shaft
3 Depth for knocking in pin 0
10 –
-0.5
Delivery Standard
Rotating Delivery
pressure delivery
{MPa amount –
– Oil: EO10-CD (rpm) (l/min)
(kg/cm2)} (l/min)
20.6
3,500 67.6 62.4
{210}
HM400-2 27
Differential lock pump (Machine with differential lock differential)

SBR(1)8+8
Unit: mm

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside Replace
2 0.060 – 0.119 0.20
outside of diameter of gear
shaft
Delivery Standard
Rotating Delivery
pressure delivery
{MPa amount
– Oil: EO10-CD (rpm) (l/min) –
(kg/cm2)} (l/min)
20.6
3,500 25.2 23.7
{210}
28 HM400-2
HM400-2 29

© 2009 KOMATSU
All Rights Reserved
30 HM400-2
SEN00524-01
HM400-2

HM400-2 2001 and up

Cab and its attachments
ROPS cab ....................................................................................................................................................... 2
Cab tilt............................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 4
Rear view monitor ......................................................................................................................................... 12
Controller related .......................................................................................................................................... 15
HM400-2 1
ROPS cab 1
1. Front glass
2. Front wiper
3. Washer tank
4. Front working lamp
5. Door (left)
6. Radio antenna
7. KOMTRAX GPS antenna (if equipped)
8. Rear glass
9. Rear wiper
10. Air conditioner fresh air filter
11. Door (right)
2 HM400-2
Cab tilt 1
1. Tilt stopper bar

2. Tilt cylinder
3. Breather
4. Adapter
5. Pin
HM400-2 3
Air conditioner 1
1. Air conditioner unit Function

2. Fresh filter • The air conditioner makes a pleasant operating
3. Control panel environment for the operator and acts to reduce
4. Compressor fatigue.
5. Receiver dryer
6. Condenser Specifications
A: To compressor Refrigerant used HFC134a (R134a)
B: From receiver dryer Refrigerant refilling level (g) 1,200 ± 50
C: To heater (engine coolant)
D: From heater (engine coolant)
4 HM400-2
Refrigerant flow system
Table of tightening torque for refrigerant piping adapter

• Condenser refrigerant outlet side

• Connecting part to cab 12 – 15 Nm {1.2 – 1.5 kgm}
A
(Between receiver drier and air conditioner (Screw size: M16 x 1.5)
unit)
20 – 25 Nm {2.0 – 2.5 kgm}
B • Condenser refrigerant inlet side
(Screw size: M22 x 1.5)
• Connecting part to cab 30 – 35 Nm {3.0 – 3.5 kgm}
C Retighten
(Between air conditioner unit and compressor) (Screw size: M24 x 1.5)
8 – 12 Nm {0.8 – 1.2 kgm}
D • Receiver refrigerant piping lock bolt
(Screw size: M6 bolt of receiver)
20 – 25 Nm {2.0 – 2.5 kgm}
E • Compressor refrigerant piping lock bolt
(Screw size: M8 bolt of compressor)
8 – 12 Nm {0.8 – 1.2 kgm}
F • Air conditioner unit refrigerant piping lock bolt
(Screw size: M6 bolt of air conditioner unit)
HM400-2 5
Air conditioner unit
1. Face outlet port Outline

2. Face outlet port • The vertical air conditioner unit on which evapo-
3. Ambient air inlet port rator and heater core is synchronized with the
4. Hot and cool box duct connecting port blower and intake unit to generate cool and hot
5. Internal air inlet port air.
6. Foot outlet port • The temperature adjusting switch on the air con-
7. Defroster output port ditioner panel controls air mix dampers and to
adjust the spurting out temperature.
A: Refrigerant gas inlet side
B: Refrigerant gas outlet side Cooler
C: Hot water outlet port • The cooler circulates refrigerant through evapo-
D: Hot water inlet port rator to cause heat exchange (dehumidification
E: Drain port and cooling).
• Air taken in by the blower and intake unit is
cooled with evaporator and then blown out from
the grille through the duct.
Heater
• The heater circulates engine coolant in heater
core to cause heat exchange (heating).
• Air taken in by the blower and intake unit is heat-
ed with heater core and then blown out from the
grille through the duct.
6 HM400-2
Receiver dryer
1. Pressure switch Function

2. Label • It is used to store liquefied high-pressure, high-
temperature misty refrigerant from the condens-
A: Refrigerant gas inlet port er. It is capable of completely liquefying the re-
B: Refrigerant gas outlet port frigerant even when bubbles are contained in
refrigerant due to the condenser condition in
heat dissipation.
• It eliminates foreign substances in the circulation
circuit and water content in the refrigerant by use
of the built-in filter and desiccating agent.
• Sight glass allows inspecting flow of the refriger-
ant.
Specifications
Effective cubic capacity (cm3) 578

Mass of desiccating agent (g) 300
HM400-2 7
Condenser
1. Fin Function
2. Tube • The condenser cools and liquefies the high-
pressure and high-temperature refrigerant gas
A: Refrigerant gas inlet port compressed by the compressor.
B: Refrigerant gas outlet port
a If the fin crushes or is clogged with dusts, heat
exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface (m )
2 6.55
Max. pressure used (MPa {kg/cm }) 2 3.6 {3.6}
8 HM400-2
Compressor
1. Case Function
2. Clutch • Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evaporator
A: Suction service valve to high-pressure, high-temperature gas so that it
B: Discharge service valve may be easily regenerated (liguefied) at normal
temperature.
• Its built-in magnet clutch turns on or off depend-
ing on the evaporator temperature and refriger-
ant pressure.
Specifications
Number of cylinder – Bore x Stroke (mm) 5 – 35 x 28.6
Piston capacity (cc/rev) 138
Allowable maximum speed (rpm) 4,000
HM400-2 9
Air conditioner panel
Display section
Display
No. Display type Display item Display range Display method Remarks
color
Outlet air All segments of current level and below
1 See above figure
temperature light up (Display in 8 levels).
Gauges
All segments of current level and below
2 Air flow rate See above figure
light up (Display in 4 levels).
RECIRC or FRESH is displayed accord-
RECIRC and RECIRC or
3 ing to RECIRC/FRESH selector switch
FRESH air FRESH air
position.
Turning "ON" of Black LCD
Air condi- When air conditioner switch is turned
4 air conditioner
tioner "ON", lamp lights up.
Pilot switch
Turning "ON" of When DEF switch is turned "ON", lamp
5 DEF air flow
DEF switch lights up.
FACE, FACE/ FACE, FACE/FOOT or FOOT air outlet is
6 Mode FOOT of FOOT displayed according to mode selector
mode switch position.
10 HM400-2
Switch section
No. Name Function Operation
RECIRC
Switch to select RECIRC or FRESH air
7 RECIRC/FRESH switch I O
(Pilot display on display section changes according to setting)
FRESH
8 Air conditioner switch Switch to turn ON and OFF air-conditioning function. OFF io ON
Switch to turn ON and OFF main power supply for air conditioner
9 ON/OFF switch ON: Setting in "OFF" state is displayed on display section. OFF io ON
OFF: Display section is turned OFF and fan is stopped.
Switch to control air flow from fan
10 Fan switch
(Control in 4 levels [LO, M1, M2, HI]) LO io HI
Low temperature
Switch to control outlet air temperature
11 Temperature control switch I O
(Control in 8 levels)
High temperature
12 DEF switch Switch to turn ON and OFF defroster OFF io ON
FACE
Switch to change air outlet position O
13 Mode selector switch (3 modes [FACE, FACE/FOOT, FOOT]) FACE/FOOT
If pressed in DEF mode, setting before DEF mode is selected. O
FOOT
Outline
• CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
• The self-diagnosis function of CPU makes the
troubleshooting easier.
Input and output signals
JAE IL-AG5-14P JAE IL-AG5-22P

Pin Input/output Pin Input/output
Signal name Signal name
No. signals No. signals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
3 Internal/external
air changeover damper ac- 3 Blower motor relay Input
Input
tuator limiter Internal/external air changeover damper
4 actuator output 1 Output
4 NC —
5 Evaporator temperature sensor Input Internal/external air changeover damper
5 Output
6 NC — actuator output 2
7 Starting switch (ON) Input 6 Mode selector actuator output 2 Output
8 Night lamp signal Input 7 Mode selector actuator output 1 Output
9 NC — 8 Air mix damper actuator output 2 Output
10 NC — 9 Air mix damper actuator output 1 Output
11 NC — 10 Actuator potentiometer power supply (5V) —
12 NC — 11 NC —
13 NC — 12 NC —
14 NC — 13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
HM400-2 11
Rear view monitor 1

(If equipped)
1. Monitor
2. Camera
3. Cable
12 HM400-2
Monitor
1. Auto switch Specifications

2. Manual switch TV signal method:
3. Zoom/Iris switch As per Japanese standard TV method
(Reverse light compensation switch) Scanning method: 2:1 Interlace method
4. Bright/Dim light selector switch CRT: 4.5 inch, black and white, 90-deg. deflection
5. Mark switch Resolution:
Horizontal 400 lines and vertical 300 lines
6. Contrast adjustment knob
Power supply voltage: DC 24/12 V
7. Brightness adjustment knob
HM400-2 13
Camera
1. Camera Specifications
2. Connector TV signal method:
As per Japanese standard TV method
Scanning method: 2:1 Interlace method
Image sensor:
1/4 inch color CCD with 250,000 pixels
Lens: 1.7 mm, 1:2.8
Angle of view: Horizontal; Approx. 118 deg.,
Vertical; Approx. 97.6 deg.
Electronic zoom: Approx. 1.4 power
Using luminance range:
Min. luminance of object; 3 lux
Power supply voltage:
DC 5.5 V – 99.5 V for main unit
(supplied by monitor)
Power consumption: Max. 120 mA
14 HM400-2
Controller related 1
Controller layout
1. Engine controller
2. Transmission controller
3. Retarder controller
4. KOMTRAX controller (if equipped)
HM400-2 15

© 2007 KOMATSU
All Rights Reserved
16 HM400-2
SEN00525-01
ARTICULATED DUMP TRUCK

HM400-2

HM400-2 2001 and up

maintenance standard
Electrical system, Part 1
Machine monitor system ................................................................................................................................. 2
HM400-2 1
Machine monitor system
Network data
1. From machine monitor to each controller
• Switch sensor data
• Option setting data
• Model selection data
2. From each controller to machine monitor
• Display data related to each controller
• Service mode data
• Troubleshooting data
2 HM400-2
Outline
The machine monitor system is comprised of 1. Displaying trouble history data for electrical
controllers and a machine monitor. The control- components
lers on the network use the data from the sen- • Displays electrical component failure
sors installed to all parts of the machine to occurrence data from each controller
observe and control the condition of the vehicle that is saved in machine monitor
and transmit those data as network data to the • Deletes data from memory
machine monitor. The machine monitor, in 2. Displaying trouble history data for machine
return, displays these data and inform the oper- Displays machine failure occurrence data
ator of the condition of the machine. from each controller that is saved in machine
• There are two types of display on the machine monitor.
monitor: the normal mode and the service mode. 3. Real-time monitor
• The items that are always displayed for the op- Takes input, output signal, and calculation
erator are the normal mode items. Their main values recognized by each controller on
content is as follows. network and displays them in real time
1. Normal display items 4. Reduced cylinder mode
• Meters (speedometer, tachometer) This function is used to stop the supply of
• Gauges (engine coolant temperature, fuel sprayed from the fuel injector to each of
torque converter oil temperature, retard- the cylinders. This function is used for the
er oil temperature, fuel level) purpose of, for example, determining the
• Pilot display cylinder where there is defective combus-
• Service meter, odometer (character dis- tion.
play) 5. No injection cranking
2. Items displayed when there is abnormality This function is used to lubricate an engine
Caution, action code display (while an without starting the engine to drive a vehicle
action code is being displayed, press after a long-term storage.
machine monitor mode selector switch (>). 6. Adjusting function
A failure code (6-digit) is then displayed.) This function is used to correct installation
3. Maintenance monitor function errors of sensors, solenoid valves, and
When the filter, oil replacement interval is compensate production tolerances of parts
reached, the item needing replacement is and components. This function is also used
displayed in the character display. to change control characteristic data in
4. Others response to user's request.
In combination with the character display 7. Maintenance monitor
and the machine monitor mode selector This function is used to change filter oil
switch, which is used to operate the charac- replacement interval and stop the function.
ter display, the following items can be dis- 8. Operation information display function
played, set, and adjusted. This function is used to display fuel con-
1) Dozing counter (option) sumption amount per operation hour.
2) Display reverse travel distance mea- 9. Option selection function
surement value This function is used to select controller
3) Reset filter oil replacement interval information and optional equipment to be
4) Input telephone number operated.
5) Select language 10. Model selection function
Input model information to be mounted.
• To make it easier to carry out troubleshooting of 11. Initialize
the controllers on the network (including the This function is used to set the machine
monitor panel itself), a service mode function is monitor when the machine is shipped from
provided. Its main content is as follows. the factory.
HM400-2 3
Machine monitor
1. Speedometer 21. Engine oil pressure caution lamp

2. Engine tachometer 22. Brake oil pressure caution lamp
3. Retarder oil temperature gauge 23. Machine monitor, option system caution lamp
4. Torque converter oil temperature gauge 24. Engine system caution lamp
5. Engine coolant temperature gauge 25. Transmission system caution lamp
6. Fuel gauge 26. Retarder system caution lamp
7. Character display 27. Tilt caution lamp
8. Turn signal pilot lamp (R.H.) 28. Seat belt caution lamp
9. Turn signal pilot lamp (L.H.) 29. Parking brake pilot lamp
10. Front lamp high beam pilot lamp 30. Retarder pilot lamp
11. Gearshift lever position pilot lamp 31. Inter-axle differential lock pilot lamp
12. Shift indicator 32. Left and right differential lock pilot lamp
13. Lock-up pilot lamp (if equipped)
14. Shift hold pilot lamp 33. Dump body pilot lamp
15. Power mode pilot lamp (power mode) 34. Emergency steering pilot lamp
16. Power mode pilot lamp (economy mode) 35. Preheating pilot lamp
17. Central warning lamp 36. Retarder oil temperature caution lamp
18. Maintenance caution lamp 37. Torque converter oil temperature caution lamp
19. Battery charge circuit caution lamp 38. Engine coolant temperature caution lamp
20. Steering oil temperature caution lamp 39. Fuel level caution lamp
4 HM400-2
40. Rotary switch [SW1]

43. Dipswitch [SW5-4]
46. SI Spec, Non-SI Spec selection switch [SW5-1]
HM400-2 5
Machine monitor normal display functions
Q : Lights up E: Sounds intermittently

A: Q shows that all lamps light up for approx. 2 seconds after starting o all off for 1 second
Related actuation A
Immediately
No. Display Display Device Color Display range/ Method of Central after Remarks
item category conditions display Alarm starting
warning buzzer
lamp switch is
turned ON
Scale: 0 - 80 km/h or 0 - 50
Meter Movement White mph Analog — — —
Background (mph display is only display
1 Travel color: Black when non-SI is used)
speed
When side lamps light Lights up
Backlight LED Amber up when — — Q
actuated
Scale: 0 - 3400 rpm (red
White, red Analog
Meter Movement Background zone: More than 2500
display Q E —
Engine color: Black rpm)
2 speed
actuated
Scale: 50 - 150°C
Gauge White, red (red zone:
Movement Background More than Analog — — —
display
color: Black 120°C)
3 Brake Lights up
cooling oil When temperature is
36 temperature Caution LED Red more than 120°C when Q E Q
abnormal
Lights up
Backlight LED Amber When side lamps light when — — Q
up actuated
Scale: 50 - 135°C
White, red Analog
Gauge Movement Background (red zone: More than display — — —
120°C)
color: Black
Torque
4 converter Lights up
37 oil Caution LED Red When temperature is when Q E Q
temperature more than 120°C abnormal

actuated
Scale:
50 - 135°C
Gauge White, red (red zone: More than
Movement Background Analog — — —
display
color: Black 102°C)
Engine
5 coolant When temperature is Lights up
38 temperature Caution LED Red more than 102°C when Q E Q
abnormal

Backlight LED Amber when — — Q
up actuated
Scale:
Gauge White
Movement Background EMPTY-FULL Analog — — —
display
color: Black
6 Fuel level When below specified Lights up

level (amount of fuel
39 gauge Caution LED Red remaining in tank is when — — Q
actuated
less than 75 l)

actuated
Actuated
Service 0 - 65535.0h when
meter Service * Displayed on top engine is When time exceeds 65535.0h,
(normal Display running — —
display meter letters: line of character Ratio of stops at 65535.0h
Black display
7 items) LED movement
Background to time 1:1
color:
Odometer Green 0 - 999999.9km Actuated When distance exceeds
(normal * Displayed on bottom
display Odometer line of character when — — 999999.9km, stops at
traveling 999999.9km
items) display
6 HM400-2
Related actuation Immediately

Display Display range/ after
No Display item category Device Color conditions Method of display Central Alarm starting Remarks
warning buzzer switch is
lamp turned ON
When abnormality or When abnormality

failure occurs on or failure occurs on Note: Top line displays
machine machine, top line "KOMATSU", bottom
Action code Action code * Displayed on top and shows action code; — — Note displays "SYSTEM
bottom lines of bottom line CHECK"
character display displays remedy or
nature of failure
Top line displays
failure code (6
When there is digit) and
abnormality or failure, controller that See Operation &
Failure code Failure press mode switch ">". detected problem; — — Maintenance Manual for
code * Displayed on top bottom line details of failure display
and bottom lines of displays system
character display that is abnormal or
nature of
7 abnormality
Reverse
travel
distance
meter, filter, Operate machine
oil Press machine monitor monitor mode See Operation &
Other displays replacemen mode selector switch selector switch ">" Maintenance Manual for
t time reset, "<U>" or "<" to switch details of failure display
telephone screen
No. setting,
language
selection
Brightness
Night lighting Backlight LED Green When side lamps light reduced one level — — Q
up when side lamps
light up
When operated:
Right turn Lights up
8 signal LED Green When operated When not — — Q
operated: Goes
out
When operated:
Lights up
9 Left turn signal LED Green When operated When not — — Q
operated: Goes
out
When operated:
Lights up
10 High beam LED Blue When operated When not — — Q
operated: Goes
out
11
(R2 Gearshift lever
position R2 LED Green When gearshift lever is
at R2 Lights up (*) — — Q * Flashes when neutral
safety is actuated
)
11
(R1 Gearshift lever
position R1 LED Green When gearshift lever is
at R1 Lights up (*) — — Q * Flashes when neutral
safety is actuated
)
11 Gearshift lever LED Orange When gearshift lever is Lights up — — Q
(N) position N at N
11 Gearshift lever Pilot LED Green When gearshift lever is Lights up (*) — — Q * Flashes when neutral
(D) position D at D safety is actuated
11 Gearshift lever LED Green When gearshift lever is Lights up (*) — — Q * Flashes when neutral
(5) position 5 at 5 safety is actuated
(4) position 4 a4 safety is actuated
F1,F2,F3,F4,F5,F6,N,R
1,R2,R3
* According to shift
Back- range signal received When shift range
ground from transmission signal is received Q
Shift indicator LED color: controller from transmission — — All light up
12 * When alarm is
Gray actuated when making controller
emergency escape, "E-"
and "N" are displayed in
turn
Night lighting LED Amber
HM400-2 7

Display Display Display range/ Method of after
No Device Color Central Alarm starting Remarks
item category conditions display warning buzzer switch is
lamp turned ON
When torque When

operated:
converter lock-up is Lights up
13 Lock-up LED Green actuated and — — Q
transmission is set to When not
operated:
direct drive Goes out
When
operated:
When shift hold Lights up
14 Shift hold LED Green switch is operated When not — — Q
operated:
Goes out
Pilot
High power
Output mode:
mode Lights up
15 (high power LED Green High power mode When not — — Q
mode) actuated:
Goes out
Economy
Output mode:
mode Lights up
16 LED Green Economy mode — — Q
(economy When not
mode) actuated:
Goes out
Central Lights up
17 warning LED Red When there is when Q E Q
abnormality in system
lamp abnormal
When warning is Note 1: Lamp lights up and at

issued for same time action code E01 and
location for warning is displayed
18 Maintenance LED Red maintenance system, Lights up or — — Q on character display
caution or when filter, oil flashes
replacement interval Note 2: See Operation and
has passed Maintenance Manual for details
of applicable item
Battery
charge When there is Lights up
19 LED Red abnormality in charge when Q E Q
circuit circuit abnormal
caution
Steering oil Lights up
20 temperature LED Red When steering oil when Q E Q
temperature rises
caution abnormal
Engine oil Lights up
When engine oil Q E Q
21 pressure LED Red
pressure drops
when
caution abnormal
Brake oil When brake oil Lights up Note: Actuated only when
22 pressure LED Red pressure drops when Q(Note) E(Note) Q alternator R terminal = ON
caution abnormal
Machine When there is
monitor or abnormality in Lights up
23 option LED Red machine monitor or when E E Q Actually only used when failure
Caution occurs in machine monitor
system option controller abnormal
caution system
Engine When there is Lights up
24 system LED Red abnormality in engine when E E Q
caution control system abnormal
When there is
Transmission abnormality in Lights up
25 system LED Red transmission control when E E Q
caution abnormal
system
Retarder When there is
system abnormality in
caution retarder control Lights up
26 (Brake LED Red system (When there when E E Q
system is abnormality in abnormal
caution: brake control system:
E-SPEC) E-SPEC)
When dump body is
raised and there is Lights up
27 Tilt caution LED Red when Q E Q
excessive tilt to left or abnormal
right
When
actuated:
28 Seat belt LED Red When seat belt is not Lights up — — Q
caution fastened When not
actuated:
Goes out
8 HM400-2

Display Display Display range/ Method of after
No Device Color Central Alarm starting Remarks
item category conditions display warning buzzer switch is
lamp turned ON
Parking When parking brake Lights up Note: Actuated when parking
29 brake pilot Red when Q(Note) E(Note) Q brake is applied and gearshift
is applied
lamp applied lever is at position other than N
Retarder
pilot lamp When retarder brake
(Overrun is applied (When Lights up
30 protection Orange overrun protection when — — Q
brake pilot brake is applied: E- applied
lamp: E- SPEC)
SPEC)
When
Inter-axle operated:
differential Lights up when inter-
Lights up
31 lock pilot LED Orange axle differential lock is
When not — — Q
lamp operated
operated:
Goes out
Left and When
right Lights up when left actuated:
32 differential LED Orange and right differential Lights up — — Q
lock lamp lock is actuated When not
(if Pilot actuated:
equipped) Goes out
When
For details, see operated:
Body pilot Operation and Lights up Note: Actuated when gearshift
33 LED Red Q(Note) E(Note) Q
lamp Maintenance Manual When not lever is at position other than N
operated:
Goes out
When
operated:
Emergency Lights up when Lights up
34 steering LED Red emergency steering is — — Q
ready lamp actuated When not
operated:
Goes out
When
operated:
Lights up when Lights up
Preheating electric heater for Q
35 LED Red When not — —
pilot lamp engine preheating is operated:
actuated Goes out
Self-diagnostic function when operating starting switch

1. When the starting switch is turned to the ON position before starting the engine, the system check is carried
out for 3 seconds.
2. If the starting switch is turned to the START position before 3 seconds have passed with the starting switch
at the ON position, everything will go to the normal operating condition. However, even if everything goes
to the normal operating condition, the indicator gauges and meters will not work until 3 seconds have
passed after the starting switch was turned to the ON position.
HM400-2 9
Table of signals for each machine monitor connector
HM Series Monitor Panel

No. Specification
CN PIN I/O A/D
1 CN1 1 — — —
2 CN1 2 — — —
3 CN1 3 — — —
4 CN1 4 — — NSW power supply (+24V)
5 CN1 5 — — NSW power supply (+24V)
6 CN1 6 — — SW power supply (+24V)
7 CN1 7 — — SW power supply (+24V)
8 CN1 8 — — —
9 CN1 9 — — GND
10 CN1 10 — — GND
11 CN1 11 O D D_OUT_3, (Sync 200mA)
15 CN1 15 — — Sensor power output (+24 V, 100 mA)
16 CN1 16 — — Sensor power output (+5 V, 100 mA)
17 CN1 17 — — GND
18 CN1 18 — — GND
19 CN1 19 — — GND
20 CN1 20 — — GND
21 CN2A 1 I D D_IN_0 (+24 V, 5mA, PULL DOWN)
27 *1 CN2A 7 I D D_IN_12 (NSW+24 V, 5mA, PULL DOWN)
*1: NSW +24V input port is active even if the setting is made to KEY OFF when power is supplied directly from
battery.
10 HM400-2
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
— — — —
— — — —
— — — —
BAT DIRECT +24V Q Q Q Directly from battery
BAT DIRECT +24V Q Q Q Directly from battery
POWER SUPPLY +24V Q Q Q In-cab power supply
POWER SUPPLY +24V Q Q Q In-cab power supply
— — — — (–): NON CONNECT
POWER SUPPLY GND Q Q Q
POWER SUPPLY GND Q Q Q
— — — —
— — — —
BUZZER Q Q Q Warning buzzer
HEAD LIGHT H/L CHANGE Q Q Q Head lamp Hi/Low change
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
HI BEAM Q Q Q
AISS SW Q Q Q
— — — —
PASSING SW Q Q Q
CONNECTOR CHECK Q Q Q Used to detect improper connector connection
PANEL MODE SW2-1 Q Q Q Mode SW2 upper side
RIGHT TURN Q Q Q
PANEL MODE SW1-1 Q Q Q Mode SW1 upper side
HM400-2 11

No. Specification
CN PIN I/O A/D
29 CN2A 9 — — GND
38 CN2A 18 I A A_IN_0 (0 – 30 V)
39 *2 CN2B 1 I D D_IN_16 (GND, 5mA, PULL UP)
43 CN2B 5 I D D_IN_24 (+24 V, 5mA, PULL DOWN)
44 CN2B 6 — — GND
49 CN2B 11 I D D_IN_25 (+24 V, 5mA, PULL DOWN)
50 CN2B 12 I A A_IN_1 (0 – 30 V)
*1: NSW +24V input port is active even if the setting is made to KEY OFF when power is supplied directly from
battery.
*2: Setting is made to PULL UP.
12 HM400-2
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
GND Q Q Q
— — — —
— — — —
FR DIFF LOCK SW Q Q Q Front and rear differential lock switch
ENGINE MODE SW Q Q Q
PANEL MODE SW1-2 Q Q Q Mode SW 1 lower side
PANEL MODE SW2-2 Q Q Q Mode SW 2 upper side
LEFT TURN Q Q Q
— — — —
— — — —
— — — —
AIR CLEANER Q Q Q Air cleaner clogging
HYD OIL LEVEL Q Q Q Hydraulic oil level
COOLANT LEVEL Q Q Q Coolant level
REOSTAT +24 V Q Q Q Night lighting dimmer switch ON/OFF recognition
SENSOR GND Q Q Q
RETARD COOLING FILTER Q Q Q Retarder cooling filter clogging (option)
— — — —
— — — —
— — — —
SEAT BELT Q Q Q
REOSTAT Q Q Q Night lighting luminance adjustment

(LCD unit shall be relatively adjustable using option function)
LR DIFF LOCK FOOT SW Q Q Q Left and right differential lock foot switch
LR DIFF LOCK SW1 Q Q Q Left and right differential lock 3 position switch
LR DIFF LOCK SW2 Q Q Q Left and right differential lock 3 position switch
HM400-2 13

No. Specification
CN PIN I/O A/D
54 *2 CN3A 4 I D D_IN_32 (GND, 5mA, PULL UP)

58 CN3A 8 I P P_IN_0 (0.5Vp-p)

59 CN3A 9 — — GND

62 CN3A 12 I D NC


67 CN3A 17 I P P_IN_1 (0.5Vp-p)
68 CN3A 18 — — NC
69 CN3B 1 I A A_IN_2 (Low resistance input)
70 CN3B 2 I A A_IN_4 (High resistance input)
71 CN3B 3 I A A_IN_6 (Low resistance input)
72 CN3B 4 I A A_IN_8 (0 – 5 V)
73 CN3B 5 I A A_IN_10 (0 – 5 V)
74 CN3B 6 — — SGND
77 CN3B 9 I A A_IN_7 (0 – 5 V)
78 CN3B 10 I A A_IN_9 (0 – 5 V)
79 CN3B 11 — — GND
80 CN3B 12 — — NC
81 CN4 1 — — S_NET (+)
82 CN4 2 — — S_NET (+)
83 CN4 3 — — CAN (+)
*2: Setting is made to PULL UP.
14 HM400-2
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
— — — —
CONNECTOR CHECK 2 Q Q Q NON CONNECT, Used to detect improper connector

connection
— — — —
— — — —
— — — —
GND Q Q Q GND
— Q Q Q (–): NON CONNECT
— — — —
— — — —
— — — —
— — — —
— — — —
OP7 Q Q Q for service
— — — —
— — — —
— — — —
RETARD OIL TEMP Q Q Q Retarder oil temperature sensor (center)

(MIDDLE)
FUEL LEVEL Q Q Q Fuel level sensor
— — — —
— — — —
ANALOG GND Q Q —
RETARD OIL TEMP Q Q Q Retarder oil temperature sensor (front)
(FRONT)
RETARD OIL TEMP — — Q Retarder oil temperature sensor (rear)

(REAR)
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
CAN (+) Q Q Q
HM400-2 15

No. Specification
CN PIN I/O A/D
84 CN4 4 — — S_NET (–)
85 CN4 5 — — S_NET (–)

86 CN4 6 — — GND
87 CN4 7 — — GND
88 CN4 8 — — CAN (–)
89 CN4 9 — — NC
90 CN4 10 — — NC
91 CN4 11 — — NC
92 CN4 12 — — NC
93 CN5 1 — — NC
94 CN5 2 — — RS232C_1_RTS
95 CN5 3 — — RS232C_1_RD
96 CN5 4 — — RS232C_2_RD
97 CN5 5 — — RS232C_2_RTS
98 CN5 6 — — NC
99 CN5 7 — — NC
100 CN5 8 — — RS232C_1_CTS
101 CN5 9 — — RS232C_1_TX
102 CN5 10 — — RS232C_1_SG
103 CN5 11 — — RS232C_2_SG
104 CN5 12 — — RS232C_2_TX
105 CN5 13 — — RS232C_2_CTS

106 CN5 14 — — NC
107 CN6 1 — — —
108 CN6 2 — — —
109 CN6 3 — — —
110 CN6 4 — — —
111 CN6 5 — — —
112 CN6 6 — — —
113 CN6 7 — — —
114 CN6 8 — — —
16 HM400-2
Signal and model

Model name Remarks
Signal name
HM300 HM350 HM400
— — — —
— — — —
— — — —
— (CAN SHIELD GND) — — —

CAN (–) Q Q Q
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
HM400-2 17
a Switch input on monitor panel board
No. SW Position I/O A/D Specification
1 SW1 0 I D Rotary switch (16 positions)
2 SW1 1 I D
3 SW1 2 I D
4 SW1 3 I D
5 SW1 4 I D
6 SW1 5 I D
7 SW1 6 I D
8 SW1 7 I D
9 SW1 8 I D
10 SW1 9 I D
11 SW1 A I D
12 SW1 B I D
13 SW1 C I D
14 SW1 D I D
15 SW1 E I D
16 SW1 F I D
18 SW2 1 I D
19 SW2 2 I D
20 SW2 3 I D
21 SW2 4 I D
22 SW2 5 I D
23 SW2 6 I D
24 SW2 7 I D
25 SW2 8 I D
26 SW2 9 I D
27 SW2 A I D
28 SW2 B I D
29 SW2 C I D
30 SW2 D I D
31 SW2 E I D
32 SW2 F I D
18 HM400-2
Model name
Signal name Remarks
HM300 HM350 HM400
— — — — Reserved
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
HM400-2 19
No. SW Position I/O A/D Specification
34 SW3 1 I D
35 SW3 2 I D
36 SW3 3 I D
37 SW3 4 I D
38 SW3 5 I D
39 SW3 6 I D
40 SW3 7 I D
41 SW3 8 I D
42 SW3 9 I D
43 SW3 A I D
44 SW3 B I D
45 SW3 C I D
46 SW3 D I D
47 SW3 E I D
48 SW3 F I D
49 SW5 1 I D Dip switch (2 positions)
50 SW5 2 I D Dip switch (2 positions)
51 SW5 3 I D
52 SW5 4 I D
53 SW6 1 I D
54 SW6 2 I D
55 SW6 3 I D
56 SW6 4 I D
20 HM400-2
Model name
Signal name Remarks
HM300 HM350 HM400
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
ON: SI specification — — — SI specification: Unit is fixed to km/h (km)

OFF: Non-SI specification Non-SI specification: Unit is set to MPH (mile) by default, but
switchable from the service menu.
— — — —
— — — —
— — — —
— — — —
— — — —
— — — —
HM400-2 21
© 2007 KOMATSU
All Rights Reserved
22 HM400-2
SEN00526-02

HM400-2

HM400-2 2001 and up

Automatic shift control system ........................................................................................................................ 2
Transmission controller ................................................................................................................................... 5
Retarder control system................................................................................................................................ 34
Auto emergency steering system.................................................................................................................. 46
Battery disconnector switch .......................................................................................................................... 48
Dump control lever........................................................................................................................................ 50
HM400-2 1
Automatic shift control system

(Transmission control system with all-range electronic modulation)
2 HM400-2
Outline RTCDB1 (Machine monitor, retarder controller, and

• The transmission controller receives the shift po- the others) (Updated for 100 msec.)
sition signal for the gearshift lever, the accelera- No. Item
tor opening signal for the accelerator pedal, the 1 Gear speed
speed signal for the transmission, and the other 2 Shift lever position
signals from the switches and sensors. It then 3 T/C oil temperature value
automatically controls the transmission and
4 Emergency escape condition
shifts it to the optimum speed range.
5 Overrun alarm command
• In addition to the shift control, the transmission
6 Neutral safety alarm command
controller also controls the torque converter
7 Lock-up operation condition
lock-up solenoid and operates the brake, the in-
ter-axle differential lock, the hoist, and the others 8 T/M controller option setting abnormality condition
to prevent overrun. 9 T/M controller model setting abnormality condition
Each clutch pack of the each transmission 10 KEY SW C terminal condition
clutch and torque converter lock-up clutch is 11 Alternator R terminal condition
equipped with an electronically controlled mod- 12 Emergency steering operation condition
ulation valve, and each clutch pack is indepen- 13 Fuel level
dently controlled. 14 Accumulator oil pressure drop condition (front, rear)
In this way, the initial pressure, build-up ratio, 15 Engine speed
and torque-off time for each clutch is controlled 16 Engine water temperature value
according to the condition of the machine, the 17 Float caution command
hoist EPC valve (proportional solenoid valve) 18 Body seating condition
and the hoist switchover valve (ON/OFF valve) 19 ASR command (operation ON/OFF)
are controlled according to the position of the 20 ASRC operation (ready lamp)
dump control lever to operate the body. 21 ASRC setting travel speed
• The transmission shift controller uses the sig- 22 ARSC overheat alarm
nals from the switches and sensors to operate 23 Not used
the machine monitor displays and caution and
24 Parking brake operation condition
pilot lamps, and transmits these data to the net-
25 Retarder brake operation condition
work.
26 Tail lamp operation
27 Retarder oil temperature (front)
Data item transmitted from the transmission 28 Retarder oil temperature (rear)
controller to the network. 29 Auto sus mode
30 RCM controller option setting abnormality condition
RTCDB1 (Machine monitor, retarder controller, and 31 RCM controller model setting abnormality condition
the others) (Updated for 10 msec.) 32 Shift hold condition
33 Rear tipping alarm command
No. Item
34 Inter-axle differential lock operation condition
1 T/M output shaft rotation number
35 Overrun prevention operation condition
2 Brake command amount (front wheel) 36 Left and right differential lock operation command
3 Brake command amount (rear wheel) 37 Engine preheat
38 Body positioner voltage
RTCDB1 (dedicated to +83) (Updated for 10 msec.) 39 Instantaneous fuel consumption
No. Item 40 Hydro-retarder oil temperature
1 Throttle correction value 41 Input shaft rotation number
2 Throttle lower limit 42 Output shaft rotation number
3 Throttle upper limit 43 L/U clutch command
4 2nd method throttle 44 HL clutch engagement command
5 HSI line / brake point rotation number 45 HL clutch release command
6 Torque curve select 46 SP clutch engagement command
7 ABS reference type 47 SP clutch engagement command
8 Droop switch
RTCDB2 (dedicated to engine controller) (Updated
9 ABS droop trim
for 100 msec.)
No. Item
1 Automatic warming-up cancel flag
HM400-2 3
Data item received from the transmission con- RPC-k (irregularly updated)
troller to the network.
No. Item
1 Model selection information
RTCDB1 (Updated for 10 msec.)
2 Option selection information
No. Item [Option item]
1 Engine speed a. Maximum gear speed setting
2 Accelerator opening b. Maximum gear speed setting for the Body-up state
c. Exhaust brake equipped/ not equipped
3 Seat unoccupied judgment
d. Accelerator linked retarder provided/not provided
4 Reverse not-permitted command e. Maintenance sensor provided/not provided
5 Retarder SW (front) condition f. Parking brake interlock provided/not provided
6 Retarder SW (rear) condition g. Economy output change function E1/E2
RTCDB2 (Updated for 100 msec.)

No. Item
1 Service meter
2 Engine mode SW
3 Parking brake operation
4 Retarder brake condition
5 Foot brake (service brake) condition
6 Body seating
7 Hoist lever condition
8 Tail lamp output (secondary brake operation recognition)
9 Not used
10 Not used
11 AISS inhibit SW
12 Engine water temperature
13 Float caution
14 ASR command (operation ON/OFF)
15 ARSC operation (Ready lamp)
16 ARSC setting travel speed
17 ARSC overheat alarm
18 Exhaust brake operation
20 Retarder oil temperature (rear)
21 Auto sus mode
22 RCM controller option setting abnormality condition
23 RCM controller model setting abnormality condition
24 Accumulator oil pressure oil drop condition (front, rear)
25 Inter-axle differential lock SW
26 Accelerator linked retarder SW1
27 Accelerator linked retarder SW2
28 Accelerator pedal abnormality flag
29 Left and right differential lock SW 1 (upwardly pressed state)
30 Left and right differential lock SW2 (downwardly pressed state)
31 Left and right differential lock foot SW
33 Retarder oil temperature (mid)
34 Retarder oil temperature (rear) * HM 400-2 only
4 HM400-2
Transmission controller
Outline
• The transmission controller controls the trans- 7. It connects to the network and shares vari-
mission system. ous data with other controllers.
It has the following features and functions. 8. It receives the model selection data (what
1. It has a power mode and an economy mode, model it is mounted on) through the net-
and the gearshifting pattern can be select- work.
ed. 9. It has a self-diagnostic function which di-
2. The braking mode is the mode when the vides the input and output systems further
brake is used. By raising the gearshifting into small parts.
point and increasing the speed of the brake 10. The self-diagnostic function is displayed on
cooling pump it is possible to raise the cool- the monitor.
ing effect of the retarder and make effective 11. When an abnormality is detected, it trans-
use of the engine brake. mits the details to the network.
3. It controls the brake through the retarder 12. It uses the machine monitor to display if the
controller for the torque converter lock-up failure is still existing.
solenoid valve and overrun prevention. 13. It provides an escape function for use when
4. It controls the inter-axle differential lock so- there is a failure in the electrical system.
lenoid valve.
5. To reduce the shock when shifting gear, it
outputs the throttle correction command to
the engine controller when shifting gear and
adjusts the engine speed.
6. Speed sensors are installed at three places
(transmission input shaft, intermediate
shaft, and output shaft). This makes it pos-
sible to detect slippage of the transmission
clutches and to protect the transmission
when there is any abnormality in the hydrau-
lic system.
HM400-2 5

DEUTSCH-24P [ATC1]
No. signal No. signal
1 Hoist lever potentiometer 2 Input 13 Machine inclination angle Input
2 Body position Input 14 Steering oil temperature Input
3 T/M oil temperature Input 15 Alternator (R) terminal Input
4 — 16 Sensor power supply Output
5 Input 17 Input
6 Shift lever position N Input 18 Emergency Steering operation 1 Input
7 Hoist lever potentiometer 1 Input 19 Torque converter oil pressure Input
8 Input 20 Input
9 Torque converter oil temperature Input 21 GND (for sensor) —
10 — 22 Sensor power supply (5V) Output
11 Emergency steering operation 2 Input 23 Memory clear (hoist) Input
12 Shift hold Input 24 Start Input
DEUTSCH-40P(1) [ATC2]
1 Output 21 Input/output
2 Input 22 Network Low Input/output
3 Engine oil filter condition (if equipped) Input 23 Input/output
4 Input 24 Input
5 Shift lever position 5 Input 25 Shift lever position R1 Input
6 Shift lever position 1 Input 26 Shift lever position 3 Input
7 Emergency escape switch Input 27 Input
8 Output 28 Input
9 Output 29 GND (for output shaft rotation input, differential gear rotation) —
10 T/M output rotation sensor Input 30 T/M output shaft rotation Input
11 Output 31 —
12 — 32 Network High Input/output
13 Engine oil level Input 33 Input/output
14 Output 34 —
15 Shift lever position D Input 35 Shift lever position R2 Input
16 Shift lever position 2 Input 36 Shift lever position 4 Input
17 Input 37 T/M oil filter condition Input
18 Output 38 Input
19 Output 39 GND (for input shaft rotation input, intermediate shaft rotation input) —
20 T/M intermediate shaft rotation Input 40 T/M input shaft rotation Input
DEUTSCH-40P(2) [ATC3]
Pin Signal name
Input/output Pin Signal name Input/output
1 Power supply 24V Input 21 GND Input
2 Proportional solenoid power supply 24V Input 22 Proportional solenoid power voltage 24V Input
3 ECM output Low, 2 nd, Hoist, Eps, Kichou (-) Input 23 ECM Rev, 3 rd, lock-up, Inter-axle differential lock (-) Input
4 Output 24 Key SW ACC Input
5 ECMV 2nd (+) Output 25 ECMV Rev (+) Output
6 ECMV lock-up Output 26 ECMV Hig (+) Output
7 Output 27 Output
8 Torque converter oil pressure sensor power supply (24V) Output 28 Hoist EPC valve Output
9 Fill switch 2nd Input 29 Fill switch Rev Input
10 Input 30 Fill switch High Input
11 Power supply 24V Input 31 GND Input
12 Proportional solenoid power supply 24V Input 32 GND Input
13 ECMV output High, 1 st, Hoist, Change (-) Input 33 GND Input
14 Key SW ACC Input 34 —
15 ECMV 3rd (+) Output 35 ECMV inter-axle differential lock (+) Output
16 ECMV Low (+) Output 36 ECMV 1st (+) Output
17 Hoist switchover valve Output 37 Output
18 Output 38 Kick-out solenoid (hoist) Output
19 Fill switch 3 rd Input 39 Input
20 Fill switch Low Input 40 Fill switch 1 st Input
6 HM400-2
Gearshift lever position and automatic gearshifting range

• The relationship between each gearshift position and the automatic gearshifting range is as shown in the
table below.
Gearshifting characteristics Braking mode:

• Shifting the transmission up and down is carried The shift-down point and the shift-up point are both
out according to the shift map saved in the con- raised, the engine speed is maintained at a higher
troller memory. level, and the amount of cooling oil for the retarder is
There are four types of shift map, depending on ensured to provide greater effect when the engine is
the condition of the input signals. used as a brake.
The settings for each mode are as shown in the
table below. Coasting mode:
The shift-down point and the shift-up point become
Mode Set conditions close to each other to decrease the occurrences of
Braking mode Brake signal ON
unnecessarily shifting transmission.
When either of the following conditions is fulfilled Power mode:

Coasting
1. Brake signal ON
mode
2. Accelerator idle The power mode uses the power of the machine to
the maximum to provide the maximum payload.
When the following conditions are fulfilled
1. Brake signal OFF
However, when the machine is unloaded or has only
Power mode a light load (high acceleration), an acceleration sen-
2. Accelerator pedal depressed
3. Power mode selector switch is at power sitive type variable shifting point is used. This de-
When the following conditions are fulfilled tects the acceleration of the machine and shifts the
Economy 1. Brake signal OFF transmission up sooner to provide better accelera-
mode 2. Accelerator pedal depressed tion and to improve the fuel consumption, noise, and
3. Power mode selector switch is at economy
transmission shock.
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both low-
ered, the engine speed is maintained at a lower level,
and the fuel consumption, noise, and transmission
shock are improved. In this mode, the maximum en-
gine output is limited.
HM400-2 7
Automatic gearshifting graph

• The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for
overrun prevention) ON/OFF points of each mode are as shown in the figure below.
Note: the foot brake applied and the engine speed

1. Power mode kept low by the lock-up, the brake cooling oil flow
• For the shift-up point, the optimum point be- becomes insufficient and the engine overheats
tween 2,090 and 1,730 rpm is selected accord- easily.
ing to the amount of the accelerator pedal is • If the travel speed lowers below 1 km/h or the
depressed, the acceleration of the machine, and foot brake is not applied or the lock-up is kept
the speed range. turned on for a long period, the lock-up is turned
• For the shift-down point also, the optimum point off and a gear speed proper for the travel speed
between 1,030 and 1,300 rpm is selected ac- is selected.
cording to the amount the accelerator pedal is 4. Lock-up
depressed and the speed range. • For the lock-up ON point, the optimum point be-
2. Economy mode tween 1,050 and 1,400 rpm is selected accord-
• For the shift-up point, the optimum point being to the torque converter input speed (engine
tween 1,930 and 1,730 rpm is selected accord- speed) and output speed (transmission input
ing to the amount the accelerator pedal is shaft speed), and the accelerator opening.
depressed, the acceleration of the machine, and • The lock-up OFF point when traveling in R1 or
the speed range. R2 is 1,200 rpm. The lock-up OFF point when
• For the shift-down point also, the optimum point traveling F1 or F2 is selected between 1,200 and
between 1,030 and 1,200 rpm is selected ac- 1,000 rpm according to the accelerator opening.
cording to the amount of the accelerator pedal is The lock-up OFF point when traveling in F3 to
depressed and the speed range. F6 with the foot brake or retarder brake applied
3. Braking mode is 950 rpm, with the foot brake or retarder brake
• If the travel speed lowers below 11 km/h on the not applied, it is 850 rpm.
third speed or 7 km/h on the 2nd speed while the • When the machine moves off downhill with the
foot brake is applied, the gear speed at that time accelerator pedal released, the lock-up is not
(F3, F2) is held. engaged until the accelerator pedal is de-
Accordingly, if the machine travels downhill with pressed or the boot brake is applied.
8 HM400-2
5. The auto brake ON point when traveling in F6 is If the operation is not correct, gearshifting is
2,400 rpm. restricted. (By default, the transmission shifts to
R2. The transmission is set to R1 by making
Gearshift lever positions and method of shifting the selection setting on the machine monitor.)
1) Gearshift lever position D 4) Gearshift lever position N
When shifting up (in power mode) At the neutral position, none of the transmission
I) When the gearshift lever is set at position D, the clutches are actuated.
transmission is set to F2 torque converter
range. Shift hold function
II) When the accelerator pedal is depressed, the • If the hold switch on the gearshift lever is pushed
engine speed rises and accelerates. When the once, the current gear speed is held. If the hold
transmission input shaft speed reaches 1050 - switch is pressed once again or the gearshift le-
1,400 rpm, the lock-up clutch is engaged, so the ver is operated, the gear speed can be changed.
torque converter is directly engaged and the If the travel speed lowers excessively while the
transmission is set to direct travel. gear speed is held, the gear is shifted down.
III) As the engine speed rises further and reaches When the travel speed rises again, however, the
1,730 - 2,090 rpm, the transmission shifts up to original gear speed is held.
F3.
While the transmission is shifting up, the engine Time when gear cannot be shifted
speed is also lowered (a command is output to • In the automatic shift range, to prevent mistaken
the engine controller) in order to reduce the operation caused by excessive variation in the
shock when shifting gear. speed when shifting gear, a time delay is used to
IV) Immediately after shifting up, the engine speed prevent the gears from being shifted within the
momentarily goes down, but as the machine set time.
accelerates, it rises again and the transmission • The gearshifting time delay is controlled precise-
shifts up in turn to F4 to F6 in the same way as ly by each gearshifting pattern through the use
in III) above. of the all-range electronic modulation system.
When shifting down (in power mode) The approximate values for the gearshifting pat-
I) When the load increases and the engine speed tern and gearshifting time delay are shown in
drops to 1,030 - 1,300 rpm, the transmission the diagram below.
shifts down one speed.
(For example, when traveling in F6, the trans-
mission shifts down to F5.)
While the transmission is shifting up, the engine
speed is also raised (a command is output to
the engine controller) in order to reduce the
shock when shifting gear.
II) As the engine speed goes down further and the
transmission shifts down in turn to F2, the
torque converter lock-up clutch is disengaged
and the transmission enters the torque con-
verter drive.
a In the above explanation, the set speed or actu-

ation may differ according to the travel condi-
tions. For details, see the automatic gearshifting
graph.
2) Gearshift lever positions 5, 4, 3, 2, 1

The method of shifting automatically from F1 to
F5 (F4, F3, F2) is the same as for "gearshift
lever position D" above.
3) Gearshift lever positions R1, R2
There are the gearshift lever positions for travel-
ing in reverse.
The safety functions related to travel in reverse
are the directional inhibitor and reverse safety.
HM400-2 9
Parking brake interlock function (option) When traveling forward at a speed of more than
Functional outline 1.9 km/h, even if the gearshift lever is operated
When the parking brake interlock function is actu- to positions R1 or R2, the transmission will not
ated, the speed range is shifted to the neutral posi- be shifted immediately to travel in reverse. The
tion regardless of the gearshift lever position. speed range is shifted to N and the engine
This function is actuated only when the optional speed is lowered to reduce the travel speed.
equipment is provided. When the travel speed goes below 1.9 km/h,
the transmission is shifted to REVERSE.
Actuation condition:
Parking brake = ON When traveling in reverse at a speed of more
than 7.2 km/h with the gearshift lever at position
Release condition: R2, even if the gearshift lever is operated from
1. Parking brake = OFF and the shift lever position R2 to R1, the transmission does not shift to R1.
2. Parking brake = ON, the engine speed is more When the travel speed goes below 1.9 km/h,
than 500 rpm, and the gearshift lever is operated the transmission is shifted to R1.
N o D o N o D o N o D o N within five sec-
onds When starting the engine, if the machine is
already traveling forward or in reverse at a
a For the purpose of, for example, the inspection, speed of more than 3.8 km/h, even if the gear-
to shift the speed range to a position other than shift lever is operated to a position other than N,
N with the parking brake applied the parking the machine will not move and the transmission
brake, interlock is released in the same way as will be held at N.
in the release condition 2. When the travel speed goes below 3.8 km/h, it
is permitted to move the machine off.
Safety functions (To prevent overload on power train, to improve
1) Down-shift inhibitor function durability and reliability)
If gearshift lever is operated D o 5 - 1, 5 o 4 - 4) Power train overrun prevention rear brake func-
1, 4 o 3 - 1, 3 o 2 -1, 2 o 1 tion
For example, when traveling in D (F6), even if If the engine speed rises to more than 2,400
the gearshift lever is operated to 4, the trans- rpm (more than 2,350 rpm in F6), the central
mission does not shift directly F6 o F4. It shifts warning lamp flashes and the alarm buzzer
down F6 o F5 o F4 in turn according to the sounds.
travel speed. If the engine speed rises to more than 2,450
(Even if the operator makes a mistake in opera- rpm (more than 2,400 rpm in F6), the rear brake
tion of the gearshift lever, the transmission does is automatically actuated.
not skip a gear speed. This is to prevent over- (To prevent overrun of engine, torque converter,
running of the engine.) and transmission, to improve durability and reli-
2) Neutral safety function ability)
This circuit prevents the engine from starting if 5) REVERSE safety
the gearshift lever is not at the N position, even The machine will not travel in reverse if the
if the starting switch is turned to the START dump control lever is not at FLOAT and the
position. dump body is not completely lowered.
(This is a safety circuit to prevent the machine (Turnover prevention function)
from moving unexpectedly when the engine is However, if the gearshift lever is at the R1 posi-
started.) tion and the shift hold switch is pressed, it is
3) Directional inhibit function possible to travel in reverse while the switch
When traveling in reverse at a speed of more being pressed, even if the dump body is not
than 2.0 km/h, even if the gearshift lever is fully lowered.
operated to D or positions 5 to 1, the transmis- 6) Speed range limit function when dump body is
sion will not be shifted immediately to travel for- raised
ward. The engine speed is lowered to reduce After dumping the load, if the body is not com-
the travel speed, and when the travel speed pletely lowered, shifting up is limited.
goes below 3.8 km/h, the transmission is shifted If the gearshift lever is at D, the machine starts
to FORWARD. in F2. If the former is at positions 5 to 1, the lat-
(To prevent overload on power train, to improve ter starts in F1. The gear is not shifted up until
durability and reliability) the body is completely lowered.
10 HM400-2
Self-diagnostic function
• The controller carries out self-diagnosis of the
system and displays any abnormalities.
• The details of the self-diagnosis are displayed
on a monitor.
• If any abnormality is detected by the self-diagno-
sis function, the abnormality data is transmitted
to the network and is displayed as an action
code on the machine monitor. The transmission
system caution, warning lamp, or alarm buzzer
may also be actuated.
Overload prevention traction force limit function

• To prevent overload on power train, there is pro-
vided a function to restrict the upper limit of the
throttle for each speed ranges "R1".
The details are shown in the diagram blow.
HM400-2 11
Transmission controller list of real-time monitoring display contents

With a real-time monitor function of a machine monitor, I can confirm a state of a controller input and output sig-
nal.
Real-time monitoring display items related to transmission controller, and contents displayed when there is nor-
mality are as follows.
No. Item ID number Displayed spec Data contents
1 Software part number 20201 VERSION Mass production software part number is output
2 Application version 20223 VERSION (APP) Software version is output (Soft logic part version)
3 Data version 20224 VERSION (DATA) Software version is output (Soft logic part version)
4 T/M input axis rotation 31200 T/M SPEED:IN Input axis rotation speed is output
5 T/M intermediate axis 31300 T/M SPEED:MID Intermediate axis rotation speed is output
rotation
6 T/M output axis rotation 31400 T/M SPEED:OUT Output axis rotation speed is output
7 T/M differential axis 31402 T/M DIFF OUT Differential axis rotation speed is output
rotation
8 Alternator R 04301 ALTERNATOR R Alternator R terminal input state (A_IN_0) is output
9 T/C oil temperature 30100 T/C OIL TEMP T/C oil temperature (A_IN_1) of oil temperature value is
output
10 T/C oil temperature 30101 T/C OIL TEMP T/C oil temperature (A_IN_1) of search voltage value is
output
11 T/M oil temperature 32500 T/M OIL TEMP T/M oil temperature of oil temperature value is output
12 HM400-2
Data range Remarks
Depending upon software part number
Depending upon software version
Depending upon software version
x1 [min-1] (0 – 32767 [min-1])

---- [Besides the above]
x1 [min-1] (0 – 32767 [min-1])

x1 [min-1] (0 – 32767 [min-1])

x1 [min-1] (0 – 32767 [min-1])

0: OFF
1: ON
x1 [°C] (0 – 150 [°C])

x1 [mV] (0.00 – 5.00 [V])

4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20V = 100°C
1.61 V = 120°C
x1 [°C] (0 – 150 [°C])

HM400-2 13
12 T/M oil temperature 32501 T/M OIL TEMP T/M oil temperature of search voltage value is output
13 S/T oil temperature 32701 STRG OIL TEMP S/T oil temperature (A_IN_4) of oil temperature value is
output
14 S/T oil temperature 32702 STRG OIL TEMP S/T oil temperature (A_IN_4) of search voltage value is
output
15 T/C oil temperature 32600 T/C OIL PRESS T/C oil temperature (A_IN_3) of pressure ratio voltage
value is output
16 T/C oil temperature 32605 T/C OIL PRESS T/C oil temperature (A_IN_3) of input voltage value is
output
17 Clutch FILL SW 38921 FILL HLR123 Every each clutch of FILL SW recognition condition is
output
18 Solenoid output (H) 31600 ECMV H DIR HIGH clutch of ECMV output direction current is output
14 HM400-2
Data range Remarks
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
x1 [°C] (0 – 150 [°C])
x1 [mV] (0.00 – 5.00 [V])
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
x1 [MPa] (0.00 – 5.00 [MPa])
x1 [mV] (0.00 – 5.00 [V])

[1 (ON), 0 (OFF)] by data to support right under HLR123 I H: H Fill SW recognition [1:ON, 0:OFF]
attend and display L: L Fill SW recognition [1:ON, 0:OFF]
R: R Fill SW recognition [1:ON, 0:OFF]
Example 1: One Fill SW recognition [1:ON, 0:OFF]
010100: F1 time 2: Two Fill SW recognition [1:ON, 0:OFF]
001010: R2 time 3: Three Fill SW recognition [1:ON, 0:OFF]
000000: N time
100010: F4 time
x1 [mA] (0 – 1000 [mA])
HM400-2 15
19 Solenoid output (L) 31601 ECMV L DIR LOW clutch of ECMV output direction current is output
20 Solenoid output (1st) 31602 ECMV 1 DIR 1st clutch of ECMV output direction current is output
21 Solenoid output (2nd) 31603 ECMV 2 DIR 2nd clutch of ECMV output direction current is output
22 Solenoid output (3rd) 31604 ECMV 3 DIR 3rd clutch of ECMV output direction current is output
23 Solenoid output (R) 31606 ECMV R DIR REV clutch of ECMV output direction current is output
24 Solenoid output (L/U) 31609 ECMV LU DIR L/U clutch of ECMV output direction current is output
25 Solenoid output (DIFF) 31607 ECMV D DIR Differential of ECMV output direction current is output
26 Angle sensor 32900 ANGLE SENSOR Angle sensor input (A_IN_8) of angle sensor ratio value
is output
27 Angle sensor 32902 ANGLE SENSOR Angle sensor input (A_IN_8) of voltage value is output
28 Brake output (front 44900 BK OUTP DIR F
wheel) direction value
29 Brake output (Rear 44901 BK OUTP DIR R
wheel) direction value
30 Throttle modified value 36000 THROTTLE MOD Throttle modified value is output sent to engine controller
31 Body positioner 34603 BODY POSITION A_IN_6
16 HM400-2
Data range Remarks
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [° ] (-25.0 – +25.0 [° ])
x1 [mV] (0.00 – 5.00 [V])
x1 [%] (0 – +100.0 [%])
x1 [%] (0 – +100.0 [%])
x1 [%] (-100.0 – +100.0 [%])
x1 [mV] (0.00 – 5.00 [V])
Seating condition: 0.32 V – 0.64 V
(Factory shipped time 0.52 V)
HM400-2 17
32 Dump lever (hoist lever) 34506 DUMP LEVER 1 A_IN9
potentiometer 1
33 Dump lever (hoist lever) 34507 DUMP LEVER 2 A_IN10
potentiometer 2
34 Body seating 34600 BODY SEATING Body seating condition is output
35 Seating control direction 45100 S CNT DIR H
(Hi)
36 Seating control direction 45101 S CNT DIR L
(Lo)
37 Seating condition 45200 S CAL A
calibration value ( )
38 Cylinder stopper 45300 S CAL B
calibration value ( )
39 Seating control time (Hi) 45400 S CNT TIME H
40 Hoist EPC output 45601 HOIST EPC DIR SOL_OUT4
41 Seating control time (Lo) 45401 S CNT TIME L
18 HM400-2
Data range Remarks
x1 [mV] (0.00 – 5.00 [V])
Lower: 0.3 V – 1.57 V
Float: 1.47 V – 2.01 V
Adjustment mode: 1.91 V – 2.30 V
Hold: 2.29 V – 3.30 V
Raise: 2.60 V – 3.50 V
Raise END: 3.40 V – 4.70 V
x1 [mV] (0.00 – 5.00 [V])
Lower: 4.7 V – 3.43 V
Float: 3.53 V – 2.99 V
Adjustment mode: 30.9 V – 2.70 V
Hold: 2.71 V – 1.70 V
Raise: 2.40 V – 1.50 V
Raise END: 1.60 V – 0.30 V

0: Except seating
1: Seating
x1 [mA] (0 – 1000 [mA])
x1 [mA] (0 – 1000 [mA])
x1 [mV] (0.00 – 5.00 [V])
x1 [mV] (0.00 – 5.00 [V])
x1 [s] (0.0 – 10.00 [s])
x1 [mA] (0 – 1000 [mA])
x1 [s] (0.0 – 10.00 [s])
HM400-2 19
42 Low clutch trigger 38900 TRIGGER MOD L Low clutch trigger compensation value is output (all oil
compensation value pressure mode)
43 High clutch trigger 38901 TRIGGER MOD H High clutch trigger compensation value is output (all oil
20 HM400-2
Data range Remarks
According to the follows hex decimal
Display it in order of follows by eight
AABBCCDD
AA: Low temperature compensation value [x10msec]
BB: Inside temperature compensation value [x10msec]
CC: Normal temperature compensation value [x10msec]
DD: High temperature compensation value [x10msec]
00000000 – FFFFFFFF [00000000 – FFFFFFFF]
(Every each range: -1.28 (80) – +1.27 (7F) [sec])
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM400-2 21
44 1st clutch trigger 38902 TRIGGER MOD 1 1st clutch trigger compensation value is output (all oil
45 2nd clutch trigger 38903 TRIGGER MOD 2 2nd clutch trigger compensation value (all oil pressure
compensation value mode)
22 HM400-2
Data range Remarks
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM400-2 23
46 3rd clutch trigger 38904 TRIGGER MOD 3 3rd clutch trigger compensation value (all oil pressure
compensation value mode)
47 Revolution clutch trigger 38906 TRIGGER MOD R Revolution clutch trigger compensation value (all oil
24 HM400-2
Data range Remarks
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM400-2 25
48 Trigger initial learning flag 38922 TRIG HLR123 Output an early condition of learning flag state of trigger
time every each clutch
[H, L, R, 1, 2, 3]
Display it in order of follows by eight columns of

indication
[HLR123]
H: H flag [1:ON, 0:OFF]
L: L flag [1:ON, 0:OFF]
R: R flag [1:ON, 0:OFF]
1: One flag [1:ON, 0:OFF]
2: Two flag [1:ON, 0:OFF]
3: Three flag [1:ON, 0:OFF]
49 Fill time (L) 41800 FILL TIME L LOW clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
50 Fill time (H) 41801 FILL TIME H HIGH clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
51 Fill time (1) 41802 FILL TIME 1 1st clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
52 Fill time (2) 41803 FILL TIME 2 2nd clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
53 Fill time (3) 41804 FILL TIME 3 3rd clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
54 Fill time (R) 41806 FILL TIME R REV clutch fill time value is output
x10 [msec] (0 – 2.55 [sec], No fill :0)
55 Throttle lower limit value 44201 THROT LIMIT LO Throttle lower limit value output sent to engine controller
output x0.1 [%] (0 – +100.0 [%])
56 Throttle higher limit value 44200 THROT LIMIT HI Throttle higher limit value output sent to engine controller
output x0.1 [%] (0 – +100.0 [%])
26 HM400-2
Data range Remarks
Display a learning flag ON/OFF state of a clutch to fall under

right under HLR123 in [1 or 0]
HLR123
1111111 (Finished with all clutches learning)
HLR123
0000000 (Unlearned in all clutches)
x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x10 [msec] (0 – 2550 [msec])

x0.1 [%] (0 – +100.0 [%])

x0.1 [%] (0 – +100.0 [%])

HM400-2 27
57 Input signal D_IN_0-7 40905 D-IN--0------7 Input signal condition is output
58 Input signal D_IN_8-15 40906 D-IN--8-----15 Input signal condition is output
59 Input signal D_IN_16-23 40907 D-IN-16-----23 Input signal condition is output
28 HM400-2
Data range Remarks
**0*****: Non-operation emergency steering (HM400) D_IN_2: Emergency steering relay 2 (HM400 only)
Always0 (HM300, HM350) D_IN_4: C terminal signal
**1*****: Operation emergency steering (HM400) D_IN_5: Emergency steering relay 1
****1***: Cranking D_IN_6: Shift hold SW
*****0**: Non-operation emergency steering D_IN_7: Shift lever N
*****1**: Operation emergency steering

******0*: Shift hold SW=OFF
******1*: Shift hold SW=ON
*******1: Shift lever N
*1******: L fill D_IN_9: Fill signal L
**1*****: H fill D_IN_10: Fill signal H
***1****: 1ST fill D_IN_11: Fill signal 1st
****1***: 2nd fill D_IN_12: Fill signal 2nd
*****1**: 3rd fill D_IN_13: Fill signal 3rd
******1*: R fill D_IN_14: Fill signal R
Example
01010000: F1 time
00001010: R2 time
00000000: N time
00100100: F6 time
10000000: Shift lever R2 D_IN_16: Shift range R2
01000000: Shift lever R1 D_IN_17: Shift range R1
00100000: Shift lever D D_IN_18: Shift range D
00010000: Shift lever 5 D_IN_19: Shift range 5
HM400-2 29
60 Input signal D_IN_24-31 40908 D-IN-24-----31 Input signal condition is output
61 Input signal D_IN_32 40942 D-IN-32 Input signal condition is output
62 Output signal 40949 D-OUT-0------7 ON/OFF output signal D_OUT_0-7 condition.
D_OUT_0-7 Display 0 at the time of power supply output setting.
63 Output signal 40950 D-OUT-8-----15 Supports SOL_OUT_8, 9, 10A, 10B, 11A, 11B,
D_OUT_8-15 SIG_OUT_0, SIG_OUT_1.
Display 0 at the time of power supply output setting.
64 Output signal 40951 D-OUT-16----23 Supports SIG_OUT_2, 3, HSW_OUT_0, 1,
D_OUT_16-23 BATT_RY_OUT. Not used D_OUT_21 to 23.
Display 0 at the time of power supply output setting.
30 HM400-2
Data range Remarks
0*******: TM oil filter clogging D_IN_24: TM filter switch
****0***: Dropped engine oil level D_IN_27: Emergency escape switch
*****0**: Engine oil filter clogging D_IN_28: Engine oil level
D_IN_29: Engine oil filter switch
* Plane does not use
*1**0*00: Hoist selector valve ON D_OUT_1: Hoist selector valve
****0100: Hoist lever kick-out ON D_OUT_5: Hoist lever kick-out solenoid
HM400-2 31
Hoist control function

Hoist control system diagram
1. Hoist control function reduce the shock when the dump body comes
When the engine is running, the EPC valve into contact with the chassis.
(electromagnetic proportional valve) and selec-
4. Control when starting switch is turned to ON,
tor valve are controlled according to the opera-
OFF, or START
tion of the dump control lever and operate the
Starting switch at ON:
dump body.
The output is set to HOLD, regardless of the
2. Lever positioner function position of the lever.
The dump control lever has four positions: If the engine is not started, even if the hoist
RAISE, HOLD, FLOAT, and LOWER. lever is operated, the condition remains at
If the dump control lever is operated to the HOLD.
RAISE position, the dump body is raised, and Starting switch at OFF:
when the top of the dump body reaches the set The hoist valve is closed and the dump body is
position of the body position sensor, the lever is held in position regardless of the position of the
returned to the HOLD position. lever.
Engine started:
3. Body seating speed control
Immediately after the engine is started, the out-
When the dump body is lowered and reaches
put is set to HOLD, regardless of the position of
the position just before it is seated, the area of
the lever. After the lever is moved to the HOLD
opening of the EPC valve is throttled to control
position, it becomes possible to carry out nor-
the lowering speed of the dump body and
mal operations.
32 HM400-2
5. Float caution function

In the case of "NOT FLOAT OUTPUT" or "NOT
SEATED", the float caution lamp on the monitor
panel lights up.
"FLOAT OUTPUT" and "SEATED" o Float cau-
tion OFF
"NO FLOAT OUTPUT" or "NOT SEATED" o
Float caution ON
6. Reverse inhibit function

The retarder controller judges if it is permissible
to travel in reverse or not.
"FLOAT OUTPUT" or "SEATED" o Reverse
travel permitted
"NO FLOAT OUTPUT" and "NOT SEATED" o
Reverse travel not permitted
or "LEVER RAISED" or "SEATED"
7. Calibration function
To absorb any inherent error in the dump body
potentiometer, calibration is carried out to rec-
ognize the dump body seating and the body cyl-
inder stopper condition.
After adjusting the installation of the body

potentiometer or after replacing the transmis-
sion controller, carry out calibration in the fol-
lowing order.
Order of dump control calibration (hydraulic oil
temperature: 80 - 90°C)
(1) Lower the dump body completely and run
the engine. Change the lever from HOLD
to FLOAT and check the float caution lamp
goes off.
(2) Operate the lever to the RAISE position and
raise the dump body until it contacts the
stopper. Keep the lever at the RAISE posi-
tion with the cylinder at the stopper position
for at least 5 seconds.
(3) Lower the dump body completely and keep
the lever at HOLD for at least 5 seconds.
(4) Run the engine at low idle and operate
RAISE o FLOAT with the dump body
raised to the maximum height, then lower
the dump body completely. Repeat this
operation 10 times.
(5) Run the engine at high idle and operate
RAISE o FLOAT with the dump body
raised to the maximum height, then lower
the dump body completely. Repeat this
operation 10 times.
HM400-2 33
Retarder control system
34 HM400-2
HM400-2 35
Retarder controller
Outline
The retarder controller has the following functions. 5. Transmission of network data
1. Retarder control 1) Retarder actuation, float caution, parking
The electromagnetic proportional valve for the brake actuation, exhaust brake actuation,
front and rear wheels is controlled according to inter-axle differential lock actuation, accu-
the operating angle of the retarder control lever mulator oil pressure drop warning, and other
and actuates the retarder brake. data are transmitted to the monitor panel.
2) The exhaust brake command, overrun pre-
2. Overrun prevention, retarder control when there vention, retarder command when there is
is transmission abuse abuse, and other data sent from the trans-
The electromagnetic proportional valve for the mission controller are received.
front and rear wheels is controlled based on the 3) The inter-axle differential lock actuation
command (Analog command) from the trans- command, reverse inhibit, and other data
mission controller and actuates the retarder are transmitted to the transmission control-
brake by a fixed amount. ler.
3. Left and right differential lock control

The left and right differential lock is actuated
when the low speed range (F1, F2, F3, R1, R2)
is selected based on the setting of the left and
right differential lock selector SW, and the differ-
ential lock foot switch is ON.
4. BCV (brake cooling valve) control

The BCV control transmits a command to the
BCV valve to lower the cooling flow and reduce
horse power loss when service brake and
retarder brake are not actuated.
36 HM400-2

DEUTSCH-24P [BRC1]
1 Accumulator oil pressure (rear) Input 13 Input
2 Input 14 Retarder lever Input
3 Input 15 Alternator (R) terminal Input
4 GND(SIG) — 16 SENS PWR Output
5 Retarder switch (rear) Input 17 Service brake oil pressure switch Input
6 Input 18 Velitation switch 2 Input
7 Accumulator oil pressure (front) Input 19 Input
8 Input 20 Input
9 Input 21 GND (Analog) —
10 GND(SIG) — 22 POT PWR Output
11 Retarder switch (front) Input 23 Input
12 Input 24 Velitation switch 1 Input
DEUTSCH-40P(1) [BRC2]
1 Output 21 S-NET Input/output
2 Input 22 CAN0_L Input/output
3 Input 23 CAN1_L Input/output
4 232C R x D Input 24 FWE switch Input
5 Input 25 Input
6 Input 26 Input
7 Input 27 Input
8 Output 28 Input
9 Output 29 GND (pulse) —
10 Input 30 Input
11 Output 31 GND (S_NET GND) —
12 CAN_SH — 32 CAN0_H Input/output
13 Input 33 CAN1_H Input/output
14 232C T x D Output 34 GND (232C GND) —
15 Input 35 Key switch C (engine start) Input
16 Input 36 Input
17 Memory clear switch Input 37 Input
18 Output 38 Input
19 Output 39 GND (pulse) —
20 Input 40 Input
DEUTSCH-40P(2) [BRC3]
Pin Signal name
Input/output Pin Signal name Input/output
1 VB (controller PWR) Input 21 GND (controller GND) Input
2 VIS (solenoid PWR) Input 22 VIS (solenoid PWR) Input
3 SOL_COM (solenoid common GND) Input 23 SOL_COM (solenoid common GND) Input
4 Output 24 Key SIG Input
5 Output 25 Output
6 Retarder valve (front) Output 26 Output
7 Differential solenoid (front) Output 27 Brake cooling valve (front) Output
8 Output 28 Output
9 Parking brake pressure switch Input 29 Input
10 Differential pressure switch (front) Input 30 Input
11 VB (controller PWR) Input 31 GND (controller GND) Input
12 VIS (solenoid PWR) Input 32 GND (controller GND) Input
13 SOL_COM (solenoid common GND) Input 33 GND (controller GND) Input
14 Key SIG Input 34 Reservoir —
15 Output 35 Output
16 Retarder valve (rear) Output 36 Output
17 Differential solenoid (rear) Output 37 Brake cooling valve (rear) Output
18 Output 38 Output
19 Input 39 Input
20 Differential pressure switch (rear) Input 40 Input
HM400-2 37
Retarder controller list of real-time monitoring display contens

The input and output signal states of the retarder controller can be checked with the real-time monitoring func-
tion of the machine monitor.
Real-time monitoring display items related to retarder controller and contents displayed in normal state are as
follows.
No. Item ID number Displayed spec. Data contents
1 Part No. of software 20214 VERSION Mass production software part number is output
2 Application version 20231 VERSION (APP) Software version No. is output

(soft logic part version No.)
3 Data version 20232 VERSION (DATA) Software version No. is output

(soft data part version No.)
4 Alternator R 4302 ALTERNATOR R Alternator R terminal input state (A_IN_0) is output
5 Accumulator oil pressure 35500 ACC OIL PRE F Front accumulator oil pressure (A_IN_9) conversion
(front) value is output
6 Accumulator oil pressure 35506 ACC OIL PRE F Front accumulator oil pressure (A_IN_9) voltage is
(front) output
7 Accumulator oil pressure 35501 ACC OIL PRE R Rear accumulator oil pressure (A_IN_9) conversion
(rear) value is output
8 Accumulator oil pressure 35507 ACC OIL PRE R Rear accumulator oil pressure (A_IN_9) voltage is
(rear) output
9 Brake output 33807 BK OUTP DIR F SOL_OUT6

(front wheel)
10 Brake output 33806 BK OUTP DIR R SOL_OUT7

(rear wheel)
11 Retard lever 33900 RETARD LEVER A_IN_4
38 HM400-2
Data range Remarks
Depending upon software part number.
Depending upon software version No.
Depending upon software version No.
ON [1: Operate]
OFF [0]
x1 [MPa] (0.00 – 50.0 [MPa])

---- [Other than above]
x10 [mV] (0.00 – 5.00 [V])

0.00 – 99.99
x10 [mV] (0.00 – 5.00 [V])

x1 [mA] (0 – 1000 [mA])

x1 [mA] (0 – 1000 [mA])

x10 [mV] (0.00 – 5.00 [V])

HM400-2 39
No. Item ID number Displayed spec. Data contents
12 Input signal D_IN_0--7 40932 D-IN--0------7 Input signal state of D_IN_0 – D_IN_7 are output as
they are.
13 Input signal D_IN_8--15 40933 D-IN--8-----15 Input signal state of D_IN_8 – D_IN_15 are output as
they are.
14 Input signal D_IN_16-23 40934 D-IN-16-----23 Input signal state of D_IN_16 – D_IN_23 are output as
they are.
15 Input signal D_IN_24-31 40935 D-IN-24-----31 Input signal state of D_IN_24 – D_IN_31 are output as
they are.
16 Input signal D_IN_32 40943 D-IN-32-----39 Input signal state of D_IN_32 – D_IN_39 are output as
they are.
17 Output signal 40955 D-OUT--0------7 D_OUT_0 – 7 refer to SOL_OUT_0 – 7 of CR710.

D_OUT_0-7
18 Output signal 40956 D-OUT--8-----15 D_OUT_8 – 15 refer to SOL_OUT_8, 9, 10A, 10B,

D_OUT_8-15 11A, 11B, SIG_OUT_0 and SIG_OUT_1 of CR710.
19 Output signal D_OUT_23 40957 D-OUT-16-----23 D_OUT_16 – 23 refer to SIG_OUT_2, 3,

HSW_OUT_0, 1 and BATTRY_OUT of CR710.
D_OUT_21, 22 and 23 are not used.
40 HM400-2
Data range Remarks
01010101 [1.0 is displayed under corresponding display See signal table

(number)] Input signal ON [1], Input signal OFF [0],
0 is displayed on unused part



0 or 1 [1.0 is displayed under corresponding display See signal table




HM400-2 41
Retarder control function

Retarder control system diagram
Retarder lever control

• The operating angle of the retarder lever is de-
tected by the potentiometer and a current corre-
sponding to this is output to the electromagnetic
proportional valve for the front and rear wheels
to actuate the retarder.
• Overrun prevention, retarder control when there

is transmission abuse
• The electromagnetic proportional valve for the
front and rear wheels is controlled based on the
command (Analog command) from the trans-
mission controller and actuates the retarder by a
fixed amount.
42 HM400-2
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
(1) To improve the initial response of the electro-

magnetic proportional reducing valve, the out-
put (trigger output) is set to a high value.
(2) To make the actuation of the hydraulic pressure
smooth in the low pressure range, the output is
set to a high value.
(3) In the range where the retarder is normally
used, the output is proportional to the angle of
the lever.
(4) To make the opening of the hydraulic pressure
smooth in the low pressure range, the output is
set to a low value.
HM400-2 43
Left and right differential lock output

• The left and right differential lock command is
transmitted as ON/OFF signal from the retarder
controller to actuate the left and right differential
lock solenoid (front wheel, rear wheel).
Retarder control lever

• The manual retarder potentiometer and lever
validation switches 1 and 2 are built into the le-
ver.
• The manual retarder potentiometer output is a
voltage signal matching the position of the lever
and is sent to the retarder controller.
• The lever validation switches output the ON/
OFF data for the lever position to the retarder
controller.
Dump control lever

• The dump control lever potentiometer and lever
kick-out solenoid are built into the dump control
lever.
• The dump control lever potentiometer output is
a voltage signal matching the position of the le-
ver and is sent to the retarder controller.
• The lever kick-out solenoid fixes the lever at the
RAISE position when it receives the ON signal
from the retarder controller and returns the lever
to the HOLD position when it receives the OFF
signal.
44 HM400-2
Differential lock control function

Differential lock control system diagram
1. Inter-axle differential lock control sion output shaft speed exceeds the set
The inter-axle differential lock is actuated auto- value.
matically, or manually by turning the inter-axle a The inter-axle differential lock is actuat-
differential lock switch ON/OFF. ed when electric current is output to the
electromagnetic proportional valve.
• Manual differential lock:
In the low speed ranges (F1, F2, F3, R1, 2. Left and right differential lock control (controlled
R2) or N, the inter-axle command is output by the retarder controller)
when the differential lock switch is ON. Depending on the setting of the left and right dif-
ferential lock selector switch, one of the follow-
• Emergency braking control (automatic): ing is selected:
The inter-axle differential lock command is (1) rear wheel left and right differential lock ON;
output when the travel speed is more than (2) front and rear wheel left and right differential
35 km/h and the brake is ON. lock ON; or
(3) front and rear wheel left and right differential
• Brake ON control (automatic): lock OFF.
The inter-axle differential lock command is If (1) or (2) is selected, the differential lock foot
output according to the difference in speed switch is pressed, and the speed range is low
between the front and rear axles when the (F1, F2, F3, R1, R2), the differential lock com-
brake is ON. mand is output.
• Control (automatic) when there is variation

in transmission output shaft speed:
The inter-axle differential lock command is
output when the variation in the transmis-
HM400-2 45
Auto emergency steering system
1. Hydraulic tank Outline

2. Steering oil pressure sensor • If the engine stops or an abnormality occurs in
3. Flow amp valve the hydraulic pump when the machine is travel-
4. Emergency steering pump ing, and the oil in the steering circuit goes below
5. Emergency steering motor the specified oil pressure, the auto emergency
steering system automatically actuates the
emergency steering pump to ensure the steer-
ing oil pressure and to make it possible to oper-
ate the steering. It is also possible to operate it
manually.
46 HM400-2
Emergency steering motor
1. Terminal E Function
2. Terminal M • If there is an abnormal drop in the oil pressure in
the steering circuit, the emergency steering mo-
tor receives a signal from the transmission con-
troller and drives the emergency pump.
Specifications
Type DC motor
Rated voltage 24V
Rated output 0.9kW
HM400-2 47
Battery disconnector switch

EU spec.
1. Battery disconnector switch
A (0): OFF
B (1): ON
48 HM400-2
Function
When the option "battery disconnect switch" is
equipped
• When the battery disconnect switch is equipped
and the switch is OFF (the contact is opened),
the starting switch B terminal, respective control-
lers, and other constant power supplies are all
cut out, and the state is the same as when the
battery is not connected.
• The battery disconnect switch is usually used for
substitution to take off the minus terminal of the
battery, when the machine is stored for a long
time (a month or longer), when the electrical sys-
tem is repaired, or when electrical welding is
performed.
When the battery disconnect switch is turned off, all
the electrical system of the machine will be inopera-
tive.
• The clock of the monitor/radio and reception pre-
set memory of radio will be lost, and need to be
set again when using them.
• Such functions as room lamp, step lamp, and
hazard lamp cannot be used either.
k Important
Do not turn off the battery disconnect switch
while the engine is rotating and immediately
after the engine has stopped.
If the battery disconnect switch is turned off
while the alternator is generating electricity, the
generated current has nowhere to go, leading
to overvoltage of the electrical system of the
machine, which may cause serious damage to
the electrical system such as electric devices or
controllers.
HM400-2 49
Dump control lever
50 HM400-2
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HM400-2 51
Function
• If lever (1) is operated, rod (18) moves up and
down to rotate potentiometer (16) according to
the operation stroke of the lever.
• The operation angle (stroke) of the control lever
is sensed with the potentiometer and it is output
in the form of signal voltage to the controller.
• One potentiometer is installed to output 2 oppo-
site signal voltages shown in "Output voltage
characteristics".
Operation
1. When dump control lever is set in "FLOAT"
position
• If rod (2) on the LOWER side is pushed and
moved down with lever (1), ball (14) touches
projection (a) of rod (11) on the stroke. (Before
start of mechanical detent)
• If rods (2) and (11) are pushed further, ball (14)
pushes up retainer (13) held on detent spring
(12) and escapes out to go over projection (a) of
rod (11).
• At this time, rod (18) on the opposite side is
pushed up by spring (4) and ball (14) is moved
to the small diameter side of projection (b) of rod
(19) by retainer (13) held on detent spring (20).
• Even if the operator releases the lever, rod (18)
is held by projection (b) of rod (19) and ball
pressing force, and consequently the lever is
held in the "FLOAT" position.
52 HM400-2
2. When dump control lever is returned from 4. When dump control lever is set in "RAISE"
"FLOAT" position position
• To return lever (1) from the "FLOAT" position, • If rod (18) on the RAISE side is pushed and
push it down with a force larger than the holding moved down with lever (1), ball (14) touches
force of rod (19), detent spring (20), retainer (13) projection (a) of rod (19) on the stroke. (Before
and ball (14). start of electric detent)
• If rods (18) and (19) are pushed further, ball (14)
3. When dump control lever is set in "LOWER" pushes up retainer (13) held on detent spring
position (20) and escapes out to go over projection (a) of
• If lever (1) is leaned further from the "FLOAT" rod (19).
position, it is set in the "LOWER" position. • At this time, rod (2) on the opposite side is
• Rod (18) is pushed up by spring (4) according to pushed up by spring (4).
the operation stroke of lever (1). • If rod (2) is pushed up while current is flowing in
• Since lever (17) and rod (19) installed to the solenoid (9), nut (10) is attracted by bushing (8).
turning shaft of potentiometer (16) are connect- • As a result, rod (2) is kept pushed up. Accord-
ed to each other, potentiometer (16) outputs ingly, even if the operator releases the lever, the
voltages according to the vertical stroke of the lever is held in the "RAISE" position.
rod.
5. When dump control lever is returned from

"RAISE" position
• To return lever (1) from the "RAISE" position,
push it down with a force larger than the attrac-
tion of the solenoid. It is also returned to the
"HOLD" position when the solenoid power sup-
ply is turned "OFF" and the "RAISE" operation is
reset.
HM400-2 53
© 2009 KOMATSU
All Rights Reserved
54 HM400-2
SEN04428-01

HM400-2

HM400-2 2001 and up

Payload meter (Card type).............................................................................................................................. 2
HM400-2 1
Payload meter (Card type)

Structure of system
1. Shift lever neutral detection switch (relay)

2. Body sensor
3. Inclinometer
4. Pressure sensor (for front left)
5. Pressure sensor (for front right)
6. Pressure sensor (for rear left)
7. Pressure sensor (for rear right)
8. Suspension cylinder
9. Payload meter
10. Lamp drive relay
11. External display lamp
12. Battery
13. Fuse (for external display lamp)
14. Fuse (for controller)
15. Memory card
16. Travel signal sensor
17. RS232C output (PC cable communication) socket
18. Battery charge signal (alternator terminal R)
19. Articulate angle sensor
2 HM400-2
Principle of calculation
1. Outline
The articulate dump truck is suspended by 6 wheels, front, central and rear pair of wheels. The front & rear
wheels are suspended by hydro-pneumatic suspension cylinder. The force Fr, which the rear wheel sus-
pends is equal as the force Fc, which the central wheel suspends because the central and rear wheels are
suspended by the equalizer bar.
The suspended force F = Ff + Fc + Fr = Ff + 2 × Fr
The force Ff = Af × Pf (Af: Suspension cylinder cross section, Pf: Suspension gas pressure)
2. Measurement of weight when empty 4. Correction on slope

(calibration) If the dump truck is loaded on a slope, the mea-
Drive the empty truck in the second gear at full sured weight is different from the weight mea-
throttle for 30 seconds. The payload meter measured on a level ground. To solve this problem,
sures the average of supported load F (empty the longitudinal inclination of the dump track is
truck) and uses it as the weight when empty. measured and measured weight is corrected ac-
The reason why the weight is measured while cording to the inclination angle. Correction
the truck is traveling is that the frictional resis- range of inclination angle: ± 5°
tance of the suspension cylinders must be aver-
aged by driving the truck and extracting and
retracting the cylinders. The weight measured
when empty is saved as a calibration data in the
memory in the controller.
3. Measurement of weight when full

Payload is measured by subtracting the sus-
pended force F (empty) when empty from the
suspended force F (loaded) when loaded.
The payload meter has 3 measurement meth-
ods in which the timing to measure the payload
is different.
1) Loading (during loading)
2) Traveling (during traveling)
3) Dumping (just before dumping)
These 3 methods are executed for each cycle.
The result of the one method can be recorded
for the cycle data. The method to be recorded
can be selected by the switch operation (service
check mode). Which method to be selected has
to be considered the site conditions and the cus-
tomer's needs.
Basically the accuracy of traveling method (de-
fault setting) is the best for normal conditions.
HM400-2 3
Method of using accurately 4. Dumping method (same as payload meter II

for rigid dump truck)
1. Suspension cylinder length When the dumping method is selected,
The payload meter calculate the payload by the 1) The ground in the dumping area has to be
signal of the suspension cylinder pressure sen- well maintained.
sors. Please maintained the length of the sus- 2) The incline of the loading spot has to be
pension cylinder to be within nominal length. within ± 5°. If the incline exceeds ± 5°, the
accuracy is getting worse.
2. Calibration run 3) Do not hit the dump truck to the wheel stop-
Calibration run has to be carried out when per too much. If the dump truck is hit to the
1) The dump truck is shipped to the site wheel stopper too much, the calculated
2) The dump body is modified (the weight of payload might be much higher than the
the dump truck is changed) actual payload.
3) The gas of the suspension cylinder is main- 4) When the dump truck is stopped, please
tained activate the parking brake and release the
4) Periodically (each season) service brake or retarder brake.
A flat, level and straight 100 m course is neces- 5) Please wait for raising the body until the
sary for calibration travel. If the course is not flat, pitching of the dump truck by braking is sus-
level or straight, the calibration accuracy travel pended. Normally wait for dumping for 3 to
lowers. This affects the accuracy of payload cal- 5 seconds to get accuracy after the parking
culation. brake is activated and the service brake or
retarder brake is released.
3. Traveling method
When the traveling method is selected to be
stored,
1) The accuracy of traveling method depends
on the road condition. The more flat the
road is, the more accurate. Please main-
tained the road conditions to get the higher
accuracy.
2) The accuracy of traveling method depends
on the distance of traveling. The longer the
distance is, the more accurate. It needs
100m measurement at shortest to get accu-
racy. The traveling measurement is carried
o ut only when the dump tr uck speed
exceeds 8 km/h and the incline of the road
is within ± 5°. The haul road has to contain
more than 100 m which meets the condition
above for Traveling method.
3) Rapid acceleration, braking and steering
cause that the accuracy might be worre.
4 HM400-2
5. Loading method
To keep the accuracy of loading method (including external display lamps)
1) The better maintained the ground of loading spot is, the more accurate.
2) The incline of the loading spot has to be within ± 5°. If the incline exceeds ± 5°, the accuracy is getting
worse.
3) Stop the dump truck gently. Do not change the shift to neural position until the dump truck is stopped
completely.
4) When the dump truck is stopped, please activate the parking brake and release the service brake or
retarder brake. Please stop the dump truck gently.
5) Do not load the material before the dump truck is stopped completely.
6) The controller recognize the loading is finished when the dump truck travels more than 5m after the
loading is stared.
7) The equalizer bar hit the stopper
• If the equalizer bar hit the stopper, the accuracy would become very bad.
• The payload meter detect this hit when the empty dump truck stops at the loading spot. The payload
meter detects the equalizer bar to be hit the stopper, then the error code 'F-FL' is displayed in the
payload meter display, and all the external display lamps are flashed.
• Do not load when all the external display lamps are flashed.
• If the error code 'F-FL' comes out, please move the dump truck forward a little bit and stop until the
'F-FL' disappears.
• When move the dump truck forward, please shift the transmission to drive range. When stop the
dump truck, please shift the transmission to neutral range after the dump track is completely
stopped.
6. Download
1) The payload meter stores the cycle data for 2,900 cycles (normally more than 1 month operation). If
the number of cycles exceeds 2,900, the newest data is overwritten on the oldest data. Please down-
load the data periodically and clear the all data before overwriting.
HM400-2 5
General locations of payload meter
1. Display
2. Communication "receiving" lamp
(Rx busy)
3. Communication "transmitting" lamp
(Tx busy)
4. Memory card access lamp
(CARD busy) (not used)
5. Mode switch
6. Calibration/clear switch (CAL/CLR)
7. Total/shift switch (TOTAL/SFT)
8. Light/increment switch (LIGHT/INC)
9. Memory card (not used)
10. Cover
a Communication "transmitting" lamp (3) also

lights up when the communication cable is not
connected to a PC or when there is defective
connection.
a When not inserting or removing memory card
(9), keep cover (10) closed.
6 HM400-2
Left face
a The switches are adjusted before the machine is shipped.

Do not touch any other switch.
HM400-2 7
Basic functions
1. Power ON
When the power is turned ON, all functions are checked and displayed.
Power ON
Display portion 8.8.:8.8. (3 seconds) External display lamps all ON

Buzzer sounds (green, yellow and red)
(30 sec)
Model selection code display (8 seconds)

C0 : 00 o HM400-2, HM400-2R, HM400-1
C0 : 02 o HM300-2, HM300-2R, HM300-1
Weight unit setting

US : - - o Metric tons
US : oo o Short tons (US tons)
Machine ID code (3 seconds)

d.xxx (xxx o 0 – 200 shows code for set input)
Opened ID code (3 seconds)

o.xxx (xxx o 0 – 200 shows code for set input)
Normal operation display
2. Measuring empty weight (calibration)

The weight of the dump truck when empty is measured and this is used as the calibration data.
These data are retained even when the power is turned OFF.
8 HM400-2
3. Normal operation display
Display during normal operations

Gearshift lever Dump body Payload meter External display
Condition of the machine
position position display lamps
Stopped N Seated Time OFF
When empty
Traveling Except N Seated Time OFF
Payload display and
Stopped N Seated Payload [ton]
During display of estimate
loading Traveling
Traveling (*1) Except N Seated OFF
distance [m]
Stopped N Seated Payload [ton] Payload display
When loaded
Total payload
When dumping N Seated o Unseated OFF
(*2) [100 ton]
When
abnormality is — — — See "Error code table"
happened
*1. When load is less than 50% of correct weight, display shows 0 t.
*2. The aggregate weight display is shown in units of 100 t. (rounded to the nearest 100)
4. External display lamp drive The estimated display shows the estimation of
(estimated display) the total payload when one more load is added.
The chart on the below shows the payload dis- The applicable lamp flashes to prevent over-
play level for the external display lamps during load.
the normal operation display. If current payload is 30 ton and the last bucket
This threshold can be modified by the key oper- was 7 ton for example, the green lamp is turned
ation in the service check mode. on from the table. The estimated payload for
next bucket is 37 ton. Then the yellow lamp is
Color of lamp HM400-2, HM400-2R flashed.
1 Green 18.5 tons and up If the red lamp is flashed, one more bucket
reaches over the red threshold and it will be
2 Yellow 33.3 tons and up
overloaded.
3 Red 38.3 tons and up
HM400-2 9
5. Content of memory
(for details, see Operation and Maintenance Manual)
1) Cycle data
• The period between one dumping operation and the next dumping operation is taken as one cycle and
the data are recorded.
• The cycle data are recorded when the dumping is finished.
• The maximum limit for cycle data in memory is 2,900 cycles.
• Cycle data is recorded for more than 2,600 cycles, the error message 'L:FUL' is coming out in the dis-
play.
Item Unit Range

Engine operation number Integer 1 – 65,535
Month Month 1 – 12
Day Day 1 – 31
Time hour Hour Displayed as 0 – 23
Time minute Minute 0 – 59 Displays value and set value
at time of dumping
Machine ID Integer 0 – 200
Open ID Integer 0 – 200
t (Metric ton) or
Payload 0 – 6,553.5
US ton (Short ton)
Warning items/cycle
2) Engine ON/OFF data

• Each time the engine was stopped and started is recorded.
• The maximum limit in memory for engine ON/OFF data is 115.
• If the data is over 105, the error message 'E:FUL' is coming out. In this case, please download the data
and clear the data.
Item Unit Range

Engine operation number Integer 1 – 65,535 Consecutive number for operation of engine
Year (last 2 digits) Year 0 – 99
Shows when engine was
Day Day 1 – 31
switched ON
Time minute Minute 0 – 59
Shows when engine was
Day Day 1 – 31
switched OFF
t (Metric ton) or
Aggregate payload 0 – 9,999,000 Total value between engine ON and
US ton (Short ton)
engine OFF
Total number of cycles Times 0 – 9,999
10 HM400-2
3) Abnormality, warning data

a Each time a payload meter abnormality or warning is generated or cancelled is recorded.
The maximum limit in memory for abnormality or warning data is 230 generated/cancelled sets.
Item Unit Range

Engine operation number when
Integer 1 – 65,535
error code was generated
Frequency of generation
Times 1 – 255
after engine is switched ON
Day Day 1 – 31 Shows when error code was
generated
Time hour Hour (0 – 23) Displayed as 0 – 23
Engine operation number
Integer 0 – 65,535
when cancelled
Month Month 1 – 12 Shows when error code was
cancelled
Day Day 1 – 31
Time hour Hour (0 – 23) Displayed as 0 – 23
HM400-2 11
6. Forced display of aggregate payload, total d) Forced initialization

number of cycles This forcibly deletes all the data in payload
By operating the [TOTAL/SFT] switch of payload meter. Payload meter becomes just same
meter, it is possible to carry out forcible display as the one when the controller is shipped
of these items. For details, see the Operation from the factory.
and Maintenance Manual. • Before carrying out this operation,
check the time and date. Always carry
7. Operator check mode out the operation with the machine un-
By operating the switch of payload meter, it is loaded. Do not carry out the operation
possible to carry out the following items. unless necessary.
For details, see the Operation and Maintenance • If this is carried out, the calibration data
Manual. as well as each setting are cleared. The
1) Data all clear inclinometer calibration and the calibra-
2) Machine ID setting tion run are necessary to be done again.
3) Open ID setting
4) Time, date correction
8. Dimming of display portion

It is possible to adjust the brightness of payload
meter display portion to 10 levels with the
[LIGHT/INC] switch
9. Downloading saved data

It is possible to download any data recorded in
payload meter to a PC through a cable (RS232C)
For details, see the PC software manual provid-
ed by Komatsu.
10. Service check mode

By operating the switches of payload meter, it is
possible to forcibly carry out display, setting, and
correction of the following items.
a) Detailed calibration data display
The display shows the date, suspension
pressure, etc. when the latest calibration
was carried
b) Data all clear (service area)
This forcibly deletes all the calibration data
and analog data, except for the latest cali-
bration data.
a Before clearing the data, always down-
load the data to a PC or carry out (a)
Card dump.
c) Input signal condition display
This displays some of the signal conditions
for the sensors input to payload meter and
the present recognition condition of the pay-
load meter.
12 HM400-2
e) Parameter setting
This allows to modify the parameter setting.
Display Item Unit Default Min Max

1. 5 Loading completion travel distance m 5 5 999
2. 10 Loading start threshold % 10 5 25
3. 0.0 Payload offset ton 0.0 -5.0 5.0
4.100 Payload gain % 100 80 120
5. 0.0 Loading payload offset ton 0.0 -5.0 5.0
6. 05 Travel mode min. speed km/h 8 1 20
7. 05 Travel mode max incline deg 5 5 10
8. 50 Green lamp threshold (X1) % 50 50 X2
9.090 Orange lamp threshold (X2) % 90 X1 X3
A.105 Red lamp threshold (X3) % 105 X2 120
b. 2 Store mode — 2 1 3
C. 2.0 Stopper-hit threshold ton 2.0 2.0 5.0
d. 50 Dump completion threshold % 50 10 50
E. 1.0 Stable payload threshold ton 2.0 0.5 3.0
F. 0 External display lamps check mode — 0 0 3
H.000 Machine Code (0: HM400, 2: HM300) — 0 0 0
J.000 payload unit (0: ton,1: short ton) — 0 0 1
L.000 Area code (1: Australia, 0: other) — 0 0 1
P.100 C1 % 100 80 120
U.100 C2 % 100 80 120
G.100 C3 % 100 80 120
y.100 C4 % 100 80 120
1) Loading completion travel distance 2) Loading start threshold

If the truck moves this distance after load- If the calculated payload becomes over this
ing, payload meter recognize the loading is threshold, payload meter recognizes the
completed. After the recognize of loading loading is started. And the difference
completion, the estimate function of the between the current payload and the last
external display doesn't work. The default payload is over this threshold, payload
setting is 5 m. meter recognizes one more bucket is
loaded. The default is 10%. This default
setting is for 8-bucket load or less. If the
bucket of the loader or excavator is too
small for this truck, the count of buckets
might be less than actual. In this case, this
setting has to be modified less value (7 to
8%).
HM400-2 13
3) Payload offset, payload gain 6) Travel mode max incline

If the calculated payload is different from Payload meter calculates the paylaod by
the payload measured with the scale, the averaging the data during the traveling in
former can be adjusted by this setting and the traveling mode. Normally when the
the following setting (Payload gain). How- slope is steep, the accuracy tends to be
ev er, onl y the download data can be worse. Payload meter averages the data
adjusted by this setting, and the payload only when the slope is less steep than this
displayed on the payload meter cannot be thireshold. The default setting is 5 degree.
adjusted. This setting is proper for almost all road
(The adjusted payload) = (Payload gain) × conditions. But if the major part of the haul
(Calculated payload) + (Payload off set) load has more than 5 degree slope and the
To modify these setting, do not set the value accuracy of traveling mode is not good
enough, this threshold can be modifed to
by few data because the data has deviation.
larger value (7 – 8 degree).
To do this, at least 5 cycles measuremet is
necessary.
7) Green/Yellow/Red lamp threshold
If the error is almost constant, regardless of As default, the green is set to 50%, yellow
the payload, "Payload offset" must be 90%, and red 105% similarly to a rigid
changed. For example, if the payload dump truck. If these are set severer, for
meter indicates 1 ton heavier than each of example, if the green is set to 80%, yellow
the actual loads of 25.9 ton (70%) and 37.0 95%, and red 105%, more accurate display
ton (100%), "Payload offset" must be set to is obtained. Do not set a threshold value
"-1.0". higher than 105% to the red, however.
If the error depends on the payload, both of
"Payload offset" and "Payload gain" must 8) Store mode
be changed. For example, if the payload Payload meter has 3 measurement meth-
meter indicates 1 ton heavier than the 70% ods as described before. But only 1 mea-
actual load and 2 ton heavier than the surement method is stored and can be
100% actual load, "Payload gain" must be downloaded. A mode of one type that
set to "91" (37.0 – 25.9)/(39.0 – 26.9%) and meets the jobsite condition and customer's
"Payload offset" must be set to "1.5" (37 – needs must be recommended to the cus-
0.91 x 39). tomer and must be set in the payload meter
controller.
4) Loading payload offset Guideline is
If the payload calculated at the loading time • Traveling mode is the most accurate. If
has an error but the saved payload is free not any special reason, choose travel-
ing mode.
of error, the display of the payload at the
• If the haul road is very rough or very
loading time can be adjusted by this setting.
short (less than 200 m) and the dumping
Normally the ground condition impacts to
area is well maintained, choose Dump-
the accuracy of the paylaod when loading. ing mode.
Please check the ground condition first. • If the customer wants to store the pay-
load displayed during loading, choose
5) Travel mode min. speed loading mode.
Payload meter calculates the paylaod by
averaging the data during the traveling in 9) Stopper-hit threshold
the traveling mode. Normally the ground If the equalizer bar hits to the stopper, the
condition is very rough when the vehicle accuracy of the payload when loading
speed is low. If the ground condition is very becomes very bad as described before.
rough, the accuracy tends to be worse. Payload meter recognize the hitting if the
Payload meter averages the data only calculated payload is over this threshold
when the vehicle speed is over this thresh- when the empty vehicle stops at the loading
old. The default setting is 8 km/h. This set- spot. The default setting is 2 ton. If payload
ting is proper for almost all road conditions. meter recognize the hitting, the error mes-
But if the truck speed is very slow for a long sage 'F-FL' is coming out. If this detection is
time and the accuracy of traveling mode is too sensitive, this threshold can be modifed
not good enough, this threshold can be to the higher value (3.0 ton). But this
modified to less value (5 – 6 km/h). causes the fail to detect the hitting. Please
take care when the setting is modified.
14 HM400-2
10) Dump completion threshold 16) C1, C2, C3, C4

Payload meter recognize the dump comple- The formaulation to calculate the payload is
tion when the paylaod becomes under this described simply as below.
threshold during the dumping. There is no (Calculated paylaod) = C1 x (Sum of the
need to modify this parameter. front suspension cylinder pressure) + C2 x
(Sum of the rear suspension cylinder pres-
11) Stable payload threshold sure) + C3 x (incline) + C4 (offset)
The calculated payload changes dynami- This setting can modify these parameter.
cally when loading. Payload meter waits for These parameters are set for each
the calculation until the calculated payload machine. If sufficient accuracy is not
becomes stable. This threshold is the one obtained by changing the parameters for
payload meter recognize the calculated 'payload offset' and 'payload gain', the
payload to be stable. This setting (2 ton) is above parameters need to be changed. Do
proper for almost all conditions. This not change these settings without checking
impacts to the accuracy of the estimated with the design department.
display of the external display lamps. If the
function is strange, this setting can be mod- Set value
Model
ified to be less value (1 ton). In this case, C1 C2 C3 C4
the time delay to display the lamps after HM400-1/HM400-2 100 100 100 100
loading might be longer. HM300-1 100 100 100 100
HM300-2 105 105 105 100
12) Externa display lamps check mode
This is used for the local installation of pay-
load meter. See LOCAL INSTALLATION.
13) Machine Code

" 0 " d en o te s H M4 0 0 - 2, HM 4 0 0- 2R or
HM400-1.
" 2 " d en o te s H M3 0 0 - 2, HM 3 0 0- 2R or
HM300-1.
14) Payload unit

Payload meter has 2 units for payload dis-
play. '0' means 'metric ton', '1' means 'short
ton (US ton)'.
15) Area code

If the area is in Australia, it has to be set '1'
and to be set '0' for the other area. It
impacts to the open ID in the download
data. If the area code is set '1' (Australia),
the open ID is not recorded in the download
data.
HM400-2 15
Key operation
The chart below describes the key operation tree.
(Power on)
3sec 8888
8sec C0:00 Model selection code
3sec US:-- Weight unit
3sec dX:XX Machine ID code
3sec oX:XX Open ID code
(normal display)
empty 12:34 clock

loading 34.5 payload
run 3 distance
loaded 12:34 clock
stop 34.5 payload
run 12:34 clock
dumping 12 total payload
empty 12:34 clock
(Calibration run)
CAL/CLR switch (2 sec) CAL Calibration run mode
CAL/CLR switch (2 sec) CAL Calibration run ready
>9Km/h 13 elapsed time
30sec 0.5 calculated payload
MODE switch normal display
(Open ID)
MODE switch o0:00 Open ID
(Operator check mode)

MODE switch (2 sec) o.CHE
MODE switch Cd.dP
TOTAL/SFT switch Cd.dP memory card dump ready
TOTAL/SFT switch (blank) momory card dump
MODE switch d.000 Machine ID

MODE switch :0.4 calendar set
TOTAL/SFT switch :04 year
TOTAL/SFT switch 12:23 month:date
TOTAL/SFT switch 12:23 month:date
TOTAL/SFT switch 12:34 hour:min
TOTAL/SFT switch 12:34 hour:min
MODE switch aC:LE all clear
CAL/CLR switch (2 sec) aC:LE all clear ready
CAL/CLR switch (2 sec) : executing
(Service check mode)

MODE switch +
C.HEC
LIGHT/INC switch
(Service input signal check mode)
CAL/CLR switch +
TOTAL/SFT switch (2 sec) S.CHE
CAL/CLR switch 11.50 Pressure sensor [FL] [V]

MODE switch S.CHE return to S.CHE by MODE switch
CAL/CLR switch 21.50 Pressure sensor [FR] [V]
CAL/CLR switch 31.50 Pressure sensor [RL] [V]
CAL/CLR switch 41.50 Pressure sensor [RR] [V]
CAL/CLR switch 53.00 Inclinometer [V]
CAL/CLR switch 63.80 Backup battery [V]
CAL/CLR switch 78.31 R-terminal [V]
CAL/CLR switch 83.00 Articulate sensor [V]
CAL/CLR switch 9312 Pressure sensor [FL] [MPa]
CAL/CLR switch a312 Pressure sensor [FR] [MPa]
CAL/CLR switch b312 Pressure sensor [RL] [MPa]
CAL/CLR switch C312 Pressure sensor [RR] [MPa]
CAL/CLR switch d3.12 Inclinometer[deg]
CAL/CLR switch E12.3 Articulate sensor [deg]
CAL/CLR switch F 1 Neutral signal
CAL/CLR switch H 1 Body seated signal
CAL/CLR switch J12.3 Velocity [km/h]
CAL/CLR switch L34.5 Current payload [t]
CAL/CLR switch P 2.3 Calibrate load [t]
CAL/CLR switch U 1 Vehicle state mode
CAL/CLR switch G18.0 Sensor power supply [V]
CAL/CLR switch y27.2 Power supply
CAL/CLR switch S.CHE Service check mode
16 HM400-2
MODE switch C.HEC
(Service setting mode)

TOTAL/SFT switch +
S.SEL
LIGHT/INC switch (2 sec)
CAL/CLR switch 1. 5 Loading completion travel distance [m]

MODE switch S.SEL return to S.SEL by MODE switch
CAL/CLR switch 2. 10 Loading start threshold [t]
CAL/CLR switch 3. 0.0 Payload offset [t]
CAL/CLR switch 4.100 Payload gain [%]
CAL/CLR switch 5. 0.0 Loading payload offset [t]
CAL/CLR switch 6. 05 Travel mode min. speed [km/h]
CAL/CLR switch 7. 05 Travel mode max incline [deg]
CAL/CLR switch 8. 50 Green lamp threshold [%]
CAL/CLR switch 9.090 Orange lamp threshold [%]
CAL/CLR switch A.105 Red lamp threshold [%]
CAL/CLR switch b. 2 Store mode
CAL/CLR switch C. 2.0 Stopper-hit threshold [t]
CAL/CLR switch d. 50 Dump completion threshold [%]
CAL/CLR switch E. 1.0 Stable payload threshold [t]
CAL/CLR switch F. 0 External lamps check mode
Machine Code
CAL/CLR switch H.000
0: HM400
payload unit
CAL/CLR switch J.000
0: ton, 1: short ton
Area code
CAL/CLR switch L.000
1: Australia, 0: other
CAL/CLR switch P.100 C1
CAL/CLR switch U.100 C2
CAL/CLR switch G.100 C3
CAL/CLR switch y.100 C4
CAL/CLR switch S.SEL
MODE switch C.HEC
(Service calibration mode)

CAL/CLR switch (2 sec) CAL.0
(Service calibration check mode)
CAL/CLR switch YY year of calibration
MODE switch CAL.0 Return to CAL.0 by MODE switch
CAL/CLR switch MM:DD Month:Date of calibration
CAL/CLR switch HH:mm Hour:Min. of calibration
CAL/CLR switch 4XXX Pressure sensor [FL] [MPa]
CAL/CLR switch 5XXX Pressure sensor [FR] [MPa]
CAL/CLR switch 6XXX Pressure sensor [RL] [MPa]
CAL/CLR switch 7XXX Pressure sensor [RR] [MPa]
CAL/CLR switch 8XX.X Calibration payload [t]
CAL/CLR switch CAL.0
(Inclinometer calibration)
CAL/CLR switch +
CAL.1
TOTAL/SFT switch (2 sec)
3sec CAL.2
CAL/CLR switch (2sec) CAL.2
3sec CHEC
MODE switch C.HEC
(Forcibly initialize mode)

CAL/CLR switch +
TOTAL/SFT switch +
LIGHT/INC switch (2 sec) AC:LE Forcibly initialize ready
CAL/CLR switch (2 sec) AC:LE execution
completed normal display
HM400-2 17
Key operation and the display includes Service check mode

1) Power on procedure
2) Normal display Service check mode has
3) Calibration run mode 1) Service input signal check mode
4) Open ID input 2) Service calibration data mode
5) Operator check mode 3) Service setting mode
6) Service check mode 4) Forcibly initialize mode
1) to 5) are explained in Operation and Mainte- 1) To enter the service check mode
nance Manual. The key switch operation for 6)Ser- When the display is in normal display mode,
vice check mode is explained in this section. press [MODE] switch (1) and [LIGHT/INC]
switch (2) simultaneously for more than 2 sec-
onds, 'CHEC' is flashing. This means service
check mode.
2) To return to the normal display mode

Press [MODE] switch (1), then the display is re-
turned to normal display.
18 HM400-2
1. Service input signal check mode 2) To check the signal input

• Then press [CAL/CLR] switch (1), then
1) To enter the service input signal check mode '1X.XX' (the most left digit is flashed) is dis-
• When the display is in service check mode played. The most left digit flashed shows the
('CHEC' is flashed), press [CAL/CLR] switch number of the item. X.XX means the voltage
(1) and [TOTAL/SFT] switch (2) simulta- of the pressure sensor for the front left sus-
neously for more than 2 seconds. pension cylinder.
• 'S.CHE' is flashed. This means the service • Press [CAL/CLR] switch (1) to see the next
input signal check mode. content according to the table. When [CAL/
CLR] is pressed at the last content of power
supply voltage 'y27.2', the display is re-
turned to 'S.CHE'.
• If you want to check the signal again, press
[CAL/CLR] switch (1) again.
Display Contents
11.50 Pressure sensor [FL][V]
21.50 Pressure sensor [FR][V]
31.50 Pressure sensor [RL][V]
41.50 Pressure sensor [RR][V]
53.00 Inclinometer [V]
63.80 Backup battery [V]
78.31 R-terminal [V]
83.00 Articulate sensor [V]
9312 Pressure sensor [FL] [MPa]
a312 Pressure sensor [FR] [MPa]
b312 Pressure sensor [RL] [MPa]
C312 Pressure sensor [RR] [MPa]
d3.12 Inclinometer [deg]
E12.3 Articulate sensor [deg]
F 1 Neutral signal
H 1 Body seated signal
J12.3 Velocity [km/h]
L34.5 Current payload [t]
P 2.3 Calibrate load [t]
U 1 Vehicle state mode
G18.0 Sensor power supply [V]
y27.2 Power supply
3) To return to the service check mode

Press [MODE] switch (3) at any process above,
the display is returned to service check mode
and 'CHEC' is flashed
HM400-2 19
2. Service calibration data mode 4) To enter the inclinometer calibration mode

• When the display is 'CAL0' flashed, press
1) To enter the service calibration data mode [CAL/CLR] switch (1) and [TOTAL/SFT]
• When the display is in the service check switch (2) simultaneously for more than 2
mode ('CHEC' is flashed), press [CAL/CLR] seconds.
switch (1) for more than 2 seconds. • 'CAL1' is flashed. See LOCAL INSTALLA-
• 'CAL0' is flashed. This means the service TION about the detail of this procudure.
calibration data mode.
Key operation Display
CAL/CLR switch +
CAL.1
TOTAL/SFT switch (2 sec)
3sec CAL.2
CAL/CLR switch (2 sec) CAL.2
3sec CHEC
2) To check the calibration data

• Then press [CAL/CLR] switch (1), then 'XX'
is displayed. XX means the year of the cali-
bration executed.
• Press [CAL/CLR] switch (1) to see the next
content according to the table. When [CAL/
CLR] switch (1) is pressed at the last content
of calibration paylaod [8XX.X], the display is
returned to 'CAL0'.
• If you want to check the signal again, press
[CAL/CLR] switch (1) again.
Display Content
YY Year of calibration
MM:DD Month:Date of calibration
HH:mm Hour:Min. of calibration
4XXX Pressure sensor [FL] [MPa]
5XXX Pressure sensor [FR] [MPa]
6XXX Pressure sensor [RL] [MPa]
7XXX Pressure sensor [RR] [MPa]
8XX.X Calibration payload [t]
3) To return to the service check mode

Press [MODE] switch (3) at any process above.
'CHEC' is flahsed and the display is returned to
the service check mode.
20 HM400-2
3. Service setting mode 2) To modify the parameter setting

• The most left digit flashed shows the num-
1) To enter service setting mode ber of the item selected. The 3 right digits
• When the display is in the service check are the parameter value. The flashed digit in
mode ('CHEC' is flashed), press [TOTAL/ this 3 digits is the one which is selected to be
SFT] switch (2) and [LIGHT/INC] switch (3) modified.
simultaneously for more than 2 seconds. • Press [TOTAL/SFT] switch (2) to change the
• '5.5EL' is flashed. Press [CAL/CLR] switch digit to be modified. The flashed digit moves
(1) to move to the next item. from right to left. Press [LIGHT/INC] switch
(3) to increase the value one by one.
• If [LIGHT/INC] switch (3) is pressed when
the flashed digit is '9', then change to '0'.
Display Item
1. 5 Loading completion travel distance [m]
2. 10 Loading start threshold [t]
3. 0.0 Payload offset [t]
4.100 Payload gain [%]
5. 0.0 Loading payload offset [t]
6. 05 Travel mode min. speed [km/h]
7. 05 Travel mode max incline [deg]
8. 50 Green lamp threshold [%]
9.090 Orange lamp threshold [%]
A.105 Red lamp threshold [%]
b. 2 Store mode
C. 2.0 Stopper-hit threshold [t]
d. 50 Dump completion threshold [%]
E. 1.0 Stable payload threshold [t]
F. 0 External display lamps check mode
H.000 Machine Code 0: HM400, 2: HM300
J.000 Payload unit 0: ton, 1: short ton
L.000 Area code 1: Australia, 0: other
P.100 C1
U.100 C2
G.100 C3
y.100 C4
3) To return to service check mode

Press [MODE] switch (4) then 'CHEC' is flashed
and the display is returned to the service check
mode.
HM400-2 21
4. Forcibly initialization mode
• Press [CAL/CLR] switch (1), [TOTAL/SFT]

switch (2) and [LIGHT/INC] switch (3) simul-
taneously for more than 2 seconds, then
'ACLE' is flashed.
• This means the forcibly initialize mode is
ready. Press [CAL/CLR] switch (1) for more
than 2 seconds, 'ACLE' is lighted up and the
forcibly initialize mode is started.
• If you want to cancel the process when
'ACLE' is flashed, press [MODE] switch (4)
then 'CHEC' is flashed.
• Several seconds after the forcibly initialize
mode is started, power on process is started.
It means that the forcibly initialization is com-
pleted.
a Do not carry out this forcibly initialize mode

if not necessary. All the data including the
calibration data is cleared.
a After the execution of this mode, all proce-
dure for local installation is necessary.
22 HM400-2
HM400-2 23
Error code table

External
Problems if Panel Error code
NO. Content Explanation display Trouble shooting Remarks
this happen display recorded
lamps
When engine
Battery voltage
Drop in backup is shut off, F-09 Change the battery
1
battery voltage
lower than the
stored data flashes — 000-009
to new one
nominal
might be lost
It impacts to
the function Check the signal
Disconnection Voltage of R- and F-18 condition display
2
at R terminal terminal out of range performance flashes — 000-018 check the
of payload connector PM1,
meter D01A, D01B
Check the signal

condition display
Abnormality in Voltage of sensor It impacts to F-20 ALL check the
3 sensor power power lower than
the accuracy flashes flash
000-020 connector PM2 or (*1)
source(18V) the nominal the harness for
Suspension
pressure sensors.
Short circuit or
disconnection in Check the signal
front left Voltage of pressure It impacts to F-21 ALL condition display
4
suspension sensor out of range the accuracy flashes flash
000-021 check the (*1)
pressure sensor connector SUFL,
system JPLM, PM2
Short circuit or
condition display
front right Voltage of pressure It impacts to F-22 ALL
5
000-022 check the (*1)
pressure sensor connector SUFR,
JPLM, PM2
system
Short circuit or
Check the signal
disconnection in
rear left Voltage of pressure It impacts to F-23 ALL condition display
6
000-023 check the (*1)
connector SURL,
pressure sensor
system JPLM, PM2
Short circuit or
rear right Voltage of pressure It impacts to F-24 ALL condition display
7
000-024 check the (*1)
pressure sensor connector SURR,
system JPLM, PM2
Short circuit
with power Check the signal
source for front Voltage of pressure It impacts to F-25 ALL condition display
8
left suspension sensor out of range the accuracy flashes flash
000-025 check the (*1)
pressure sensor connector SUFL,
system JPLM, PM2
Short circuit
Check the signal
with power
condition display
source for front Voltage of pressure It impacts to F-26 ALL
9
right suspension sensor out of range the accuracy flashes flash
000-026 check the (*1)
connector SUFR,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for rear Voltage of pressure It impacts to F-27 ALL
10
left suspension sensor out of range the accuracy flashes flash
000-027 check the (*1)
connector SURL,
pressure sensor
JPLM, PM2
system
Short circuit
Check the signal
with power
condition display
source for rear Voltage of pressure It impacts to F-28 ALL
11
right suspension sensor out of range the accuracy flashes flash
000-028 check the (*1)
connector SURR,
pressure sensor
JPLM, PM2
system
24 HM400-2
External
Problems if Panel Error code
NO. Content Explanation display Trouble shooting Remarks
this happen display recorded
lamps
Check the signal

Short circuit or
Voltage of condition display
disconnection in It impacts to F-31 ALL
12
inclinometer
inclinometer out of
the accuracy flashes flash
000-031 check the (*1)
range connector PCL,
system
JPLM, PM2
External
Short circuit in Check the relay
display lamp F-41 ALL
13 green external — 000-041 RPM,RPMG or
doesn't work flashes flash
display lamp harness
correctly
External
14 yellow external — 000-042 RPM,RPMY or
correctly
External
15 red external — 000-043 RPM,RPMR or
correctly
Cycle data is Download the

Cycle data Old data is L:FUL
16
memory FULL
recorded for more
over-written flashes
— 000-011 cycle data and (*2)
than 2,600 cycles clear the data
Engine data is Download the

Engine data Old data is E:FUL
17
memory FULL
recorded for more
over-written flashes
— 000-012 Engine data and (*3)
than 105 times clear the data
Calibration run
Payload meter F.CAL ALL Carry out the
18 not yet carried — —
doesn't work. flashes flash calibration run
out
Inclinometer Carry out the

Payload meter F.ICL ALL
19 calibration not — — inclinometer
doesn't work. flashes flash
yet carried out calibration
Accuracy Move the vehicle

Equalizer bar hit when loading F-FL ALL for the equalizer
20
to the stopper
—
becomes very flashes flash
—
bar not to be hit to
(*4)
bad the stopper
Too much Accuracy

F-AC ALL Steer the vehicle
21 articulated when — when dumping
flashes flash
—
straight
(*5)
dumping becomes bad
*1. Calibration run cannot be carried out when *3. Engine ON/OFF data
this has occurred. 1) If more than 105 sets are recorded
(less than 10 sets remaining) : E:FUL
*2. Cycle data memory FULL. flashes.
1) If more than 2,600 cycles are recorded
(less than 300 cycles remaining), L:FUL 2) If more sets are recorded, sets 116 and
flashes. 117 are recorded, the oldest ON/OFF
data is deleted in turn to make space to
2) If more cycle are recorded. Cycles record the new set.
2,901 and 2,902 are recorded, the older
cycle data is deleted in turn to make 3) This warning occur, please download
space to recorded the new cycle. the data and clear the all data (see
Forcibly initialization mode)
3) If this warning occur, please download
the data and clear the all data (see
Forcibly initialization mode)
HM400-2 25
*4. Equalizer bar hit the stopper

1) If the equalizer bar hit the stopper, the
accuracy would become very bad. The
payload meter detect this hit when the
empty dump truck is stopped at the
loading spot.
2) If the error code ‘F-FLEis displayed in

the payload meter display panel, please
move forward the dump truck a little bit
and stop the dump truck until the ‘F-
FLdisappears. When move the dump
truck forward, please shift the transmis-
sion to drive range. When stop the
dump truck, please shift the transmis-
sion to Neutral range after the dump
truck is completely stopped.
*5. Too much articulated when dumping

When the dumping mode is selected, the
payload is calculated just before dumping. If
the dump truck is articulated too much, the
accuracy tends to worse. The articulated an-
gle is more than 22.5 degree (half of full
range), this fault code is activated. If this
fault code is activated, please steer the
dump truck to be straight.
26 HM400-2
Local installation
1. Preparation
1) Before this procedure is carried out, check the suspension length. If the suspension length is out of
nominal range, charge or discharge the suspension gas and check the suspension length again to be
within nominal range. This process is very important to keep the accuracy of payload meter. This pro-
cess has to be done very carefully.
2) Check the dump body to be empty. If mud is on the dump body or on the chassis, clean it. It impacts
the accuracy.
3) The procedure below has to be carried out with Installation checklist for articulate dump truck payload
meter.
4) Calibration needs about 120m straight course with flat and horizontal ground.
5) The more straight, the more accurate. The more flat and horizontal, the more accurate.
6) Park the dump truck on the flat and horizontal ground.
7) Set the articulate straight. Mark the dump truck position on the ground.
8) Turn off engine.
• If 'press switch' without 'for more than 2 seconds' in the direction below, press switch for 0.5 seconds to
1 seconds.
• If you make a mistake of switch operation, MODE switch is effective for recovering in most situations.
• If you fail to the procedure below, turn off the key and start from the beginning again.
2. Payload meter controller check

1) Turn on the key switch.
2) Display '8.8.:8.8.' and buzzer sounds for 3 seconds.
3) Display 'C0:00' (it means machine model code = 0 [HM400-2]) for about 8 seconds. Buzzer sounds 1
second again (error detection for F.ICL, and F.CAL).
4) Display 'd0:00' (it means machine ID = 0) for 3 seconds.
5) Display 'o0:00' (it means open ID = 0) for 3 seconds.
6) Display 2 fault codes, 'F.ICL (inclinometer is not calibrated)' and 'F.CAL (calibration run is not exe-
cuted)' alternately. 'F-.FL' might be flashed, it's no problem.
7) If there are the other fault codes displayed, please check.
HM400-2 27
3. External display lamp check 2) Press [CAL/CLR] switch. The display is 'J._
1) Press [MODE] switch and [LIGHT/INC] _ 0' ('J' means 'payload weight unit setting
switch simultaneously for more than 2 sec- mode'. '0' means metric ton unit). If you
onds. The display flashes 'CHEC' (it means want to change the unit to short ton, press
service check mode). [TOTAL/SFT] switch, then the display is 'J._
_ 1' (short ton).
2) Press [TOTAL/SFT] switch and [LIGHT/
INC] switch simultaneously for more than 2 3) Press [CAL/CLR] switch. The display is 'L._
seconds. The display flashes 'S.SEL' (it _ 0' ('L' means 'area setting mode'. '0'
means service setting mode). means 'except Australia'). If the area is
Australia, press [TOTAL/SFT] switch, then
the display is 'L._ _ 1' (Australia).
3) Press [CAL/CLR] switch 15 times. The dis-
play is changing from '1._ _ 5' to 'f._ _ 0' ('f'
4) Press [CAL/CLR] switch. The display is
means 'external display lamp check mode').
'P.100' ('P' means 'machine C1 setting
The symbol '_' above means the 'space'.
mode). If you want to change the C1 value
to '105', press 'LIGHT/INC' switch 5 times,
4) Make sure that all the external lamps has to then the display is 'P.105'.
be flashed (it means error 'F.CAL' and Press [CAL/CLR] switch. The display is
'F.ICL' to be detected). 'U.100' ('U' means 'machine C2 setting
mode). If you want to change the C2 value
5) Press [LIGHT/INC] switch. The display is to '105', press 'LIGHT/INC' switch 5 times,
'f._ _ 1'. Make sure that only the green lamp then the display is 'U.105'.
has to be turned on. Press [CAL/CLR] switch. The display is
'G.100' ('G' means 'machine C3 setting
6) Press [LIGHT/INC] switch. The display is mode). If you want to change the C3 value
'f._ _ 2'. Make sure that only the yellow to '105', press 'LIGHT/INC' switch 5 times,
lamp has to be turned on. then the display is 'G.105'.
Set value
7) Press [LIGHT/INC] switch. The display is Model
'f._ _ 3'. Make sure that only the red lamp C1 C2 C3 C4
has to be turned on. HM400-1/HM400-2 100 100 100 100
HM300-1 100 100 100 100
8) Press [LIGHT/INC] switch. The display is HM300-2 105 105 105 100
'f._ _ 0'. Make sure that all the lamps has to
be flashed. 5) Press [MODE] switch. The display flashes
'CHEC' (it means service check mode).
9) If the lamps does not work correctly, please
check the connector around the lamps or 5. Input signal check
around the relay circuit. 1) Start engine.
4. Setting 2) Press [CAL/CLR] switch and [TOTAL/SFT]

1) Press [CAL/CLR] switch. The display is switch simultaneously for more than 2 sec-
'H.__0' ('H' means 'machine code setting onds. The display flashes 'S.CHE' (it
mode' and '0' means HM400-2 and '2' means service input signal check mode).
means HM300-2). If you want to change
the machine code to '2', press 'TOTAL/SFT' 3) Press [CAL/CLR] switch. The display is '1X
switch twice, then the display is 'H.__2' . XX' ('1' is flashed). The right 3 digit shows
(HM300). the voltage of front left suspension pressure
sensor. Write down the value on the check
Machine model Model sheet. ). If the value is out of range, check
0 HM400-1, HM400-2 the wiring or sensor install.
2 HM300-1, HM300-2
4) Press [CAL/CLR] switch. The display is '2X
. XX' ('2' is flashed). The right 3 digit shows
the voltage of front right suspension pres-
sure sensor. Write down the value on the
check sheet. ). If the value is out of range,
check the wiring or sensor install.
28 HM400-2
5) Press [CAL/CLR] switch. The display is '3X 12) Press [CAL/CLR] switch. The display is 'H_
. XX' ('3' is flashed). The right 3 digit shows _ 1' ('H' is flashed). The most right digit
the voltage of rear left suspension pressure shows the body seated signal ( 1 : seated, 0
sensor. Write down the value on the check : not seated ). Raise the dump body and the
sheet. ). If the value is out of range, check display on payload meter has to be 'H_ _ 0'.
the wiring or sensor install. Lower the dump body and the display on
payload meter has to become 'H_ _ 1'.
6) Press [CAL/CLR] switch. The display is '4X (Check on the check sheet. ). If the value is
. XX' ('4' is flashed). The right 3 digit shows not correct, check the wiring or sensor
the voltage of rear right suspension pres- install.
sure sensor. Write down the value on the
check sheet. ). If the value is out of range, 13) Press [CAL/CLR] switch. The display is 'J_
check the wiring or sensor install. _.0' ('J' is flashed). The most right digit
shows the velocity. Put the shift lever to 2nd
7) Press [CAL/CLR] switch. The display is '5X position and move the vehicle with full throt-
. XX' ('5' is flashed). The right 3 digit shows tle pedal. The display on payload meter has
the voltage of Inclinometer. ). If the value is to be around 12 Km/h. (Check on the check
out of range, check the wiring or sensor sheet. ). If the value is not correct, check
install. the wiring.
8) Press [CAL/CLR] switch. The display is '6X 14) Press [MODE] switch. The display flashes
. XX' ('6' is flashed). The right 3 digit shows 'CHEC'. Press [Mode] switch again. Display
the voltage of the backup battery. Write 2 error codes, 'F.ICL(inclinometer is not cal-
down the value on the check sheet. ). If the ibrated)' and 'F.CAL(calibration run is not
value is out of range, the backup battery executed)' alternately. 'F-.FL' might be
has to be replaced to new one. flashed, it's no problem.
9) Press [CAL/CLR] switch. The display is '7X 6. Inclinometer & articulate sensor calibration
. XX' ('7' is flashed). The right 3 digit shows 1) Start engine.
the voltage of R terminal. The voltage of R
terminal has to be more than 24V, but the 2) Inclinometer will be calibrated by measuring
maximum value of this display is around 2 opposite direction of the vehicle and by
8.3V. If the display is around 8.3V, it's OK. If averaging sensor inputs of these 2 times.
the value is out of range, check the wiring. The longitudinal incline of the ground must
be canceled. But the more horizontal the
10) Press [CAL/CLR] switch. The display is '8X ground is, the more accurate. Please find
. XX' ('8' is flashed). The right 3 digit shows the flat and horizontal area for this calibra-
the voltage of articulate sensor. (write down tion. The accuracy of the inclinometer
the value on the check sheet. ). If the value impacts the accuracy of payload meter.
is out of range, check the wiring or sensor This process has to be done very carefully.
install.

play is 'F_ _ 1' ('F' is flashed). The most
right digit shows the neutral signal ( 1 : neu-
tral, 0 : other ). Move the shift lever to 'D'
range. The display on payload meter has to
be 'F_ _ 0'. Return the shift lever to 'N'
range. The display on payload meter has to
be 'F_ _ 1'. (Check on the check sheet. ). If
the value is not correct, check the wiring.
HM400-2 29
3) Make sure the articulate to be straight. The 2) Park the dump truck on the flat and horizon-
articulate sensor will be calibrated as tal ground. Calibration run needs about 100
'straight' at this position. Please set the m straight and flat course.
articulate to be straight carefully.
3) Press [CAL/CLR] switch for more than 2
4) Press [MODE] switch and [LIGHT/INC] seconds. ' CAL.' will be flashed.
switch simultaneously for more than 2 sec-
onds. The display flashes 'CHEC' (it means 4) If you are ready to start, press [CAL/CLR]
service check mode). switch. ' CAL' will be lighted up.
5) Press [CAL/CLR] switch for more than 2 5) Shift the transmission to 2nd range.
seconds. The display flashes 'CAL.0' (ser-
vice calibration data check mode) 6) Press throttle pedal full. After the velocity
becomes over 9Km/h, the display counts up
6) Press [CAL/CLR] switch and [TOTAL/SFT] the elapsed time (seconds). Calibration run
switch simultaneously for more than 2 sec- needs 30 seconds run.
onds. 'CAL.1' (it means Inclinometer cali-
bration mode) will be displayed and the 7) After 30 seconds counted up, the current
calibration for Inclinometer and articulate calculated payload [ton] will be displayed.
sensor are executed for 3 seconds. 'CAL.2'
will be flashed after 3 seconds. 8) Stop the dump truck gently, shift the trans-
mission to neutral, turn on the parking
7) Turn around the dump truck and park the brake and release the retarder brake or ser-
dump truck with opposite direction on the vice brake. Do not change the transmission
exactly same position above. to neutral before the dump truck is stopped.
9) Write down the current payload. The dis-

played payload has to be around 0 ton
because the dump truck is empty.
10) Press [MODE] switch, then the display has

to be 'clock'. If 'F.-FL' is still flashed, please
move the dump truck and stop it gently. 'F.-
FL' must be distinguished. Do not change
the transmission to neutral before the dump
truck is stopped.
11) Write down the current payload.
8) Press [CAL/CLR] switch for more than 2 12) All external display lamp has to be turned
seconds. 'CAL.2' will be turned on and the off.
calibration for Inclinometer and articulate
sensor are calibrated for 3 seconds again 13) This calibration run has to be done periodi-
for opposite direction. 'CHEC' will be cally by the customer. Please induce the
flashed after the calibration is finished. way to do it to the customer.
9) Press [MODE] switch. The error code 8. Clock set

'F.ICL' must be turned off and only 'F.CAL' is 1) Clock is set for Japanese standard time.
flashed. This means the inclinometer cali- The date and the hour might be modified to
bration was successfully finished. 'F-.FL' the local time.
might be flashed, it's no problem.
2) Press [MODE] switch for more than 2 sec-
7. Calibration run onds. The display flashes 'oCHE' (it means
1) The weight of the empty dump truck has to operator check mode).
be calibrated because the weight of empty
dump truck might be different by the vessel 3) Press [MODE] switch. The display is 'd000'
and attachment options. (it means machine ID).
30 HM400-2
4) Press [MODE] switch. The display is '_ _ 2) Each method has its pros and cons. The
YZ' ('Z' is flashed, YZ means lower 2 digits method to be recorded has to be decided
of year. 'YZ' for 2003 is '03'). by the site condition and the customers
request.
5) If 'Z' has to be corrected, press [LIGHT/
INC] switch, then 'Z' is increased. 3) The general guide line is as below
(1) Traveling method is the most accurate
6) Press [TOTAL/SFT] switch. The display is '_ for almost site.
_ YZ' ('Y' is flashed, YZ means lower 2 dig- (2) If all the haul road is very rough or the
its of year. 'YZ' for 2003 is '03'). distance of haul road is less than 200 m,
a. If the ground of the dumping area is
7) If 'Y' has to be corrected, press [LIGHT/ flat and the incline is less than ±5°.,
INC] switch, then 'Y' is increased. dumping method can be selected.
b. If the ground of the dumping area is
8) Press [TOTAL/SFT] switch. The display is not flat or the incline is more than
'MM:dd' ('MM' is flashed, MM means month, ±5°., the dumping method cannot
dd means day). be selected.
(3) If the customer wants to have the pay-
9) If 'MM' has to be corrected, press [LIGHT/ load data at the loading spot, loading
INC] switch, then 'MM' is increased. method can be selected.
10) Press [TOTAL/SFT] switch. The display is 4) Press [MODE] switch and [LIGHT/INC]
'MM:dd' ('dd' is flashed, MM means month, switch simultaneously for more than 2 sec-
dd means day). onds. The display flashes 'CHEC' (it means
service check mode).
11) If 'dd' has to be corrected, press [LIGHT/
INC] switch, then 'dd' is increased. 5) Press [TOTAL/SFT] switch and [LIGHT/
INC] switch simultaneously for more than 2
12) Press [TOTAL/SFT] switch. The display is seconds. The display flashes 'S.SEL' (it
'HH.mm' ('HH' is flashed, HH means hour, means service setting mode).
mm means minutes ).
13) If 'HH' has to be corrected, press [LIGHT/ play is changing from '1._ _ 5' to 'b._ _ 2' ('b'
INC] switch, then 'HH' is increased. means 'store mode setting', '2' means 'trav-
eling method'). If you want to change the
14) Press [TOTAL/SFT] switch. The display is store mode, press [LIGHT/INC] switch.
'HH:mm' ('mm' is flashed ). Then the display is changing to 'b._ _ 3'
(loading method) o 'b _ _ 1' (dumping
15) If 'mm' has to be corrected, press [LIGHT/ method) o 'b._ _ 2' (traveling mode). Write
INC] switch, then 'mm' is increased. down the mode you set on the check sheet.
16) Press [MODE] switch. The display is 7) After the mode is selected, press [MODE]
'A.CLE' ('CLE' is flashed). switch. The display flashes 'CHEC' (it
means service check mode).
17) Press [MODE] switch. The clock has to be
displayed. 8) Press [MODE] switch again. The display
shows the clock.
9. Set store mode
1) This payload meter has 3 measurement
method, dumping method, traveling method
and loading method, are implemented.
These 3 methods are carried out for corre-
sponding stage of each cycle. But only the
payload by 1 method is stored and can be
downloaded. Which mode to record can be
set with the switch of the payload meter
controller.
HM400-2 31
10. Trial test

1) Try 1 cycle including loading, traveling and dumping with almost 100% payload.
2) See "Method of using accurately".
3) Check the display working correctly as the table below.
Gearshift Payload
Condition of machine Dump body position External display lamp
lever position display panel
Stopped N Seated Time OFF

When empty
Payload display and

Stopped N Seated Payload
display of estimate
During loading
Traveling
Traveling (*1) Except N Seated OFF
distance
Stopped N Seated Payload Payload display

When loaded
Total payload
When dumping N Seated o Unseated OFF
(*2)
When abnormal-
— — — See "Error code table"
ity is happened
*1. When load is less than 50% of correct weight, display shows 0 t.
*2. The aggregate weight display is shown in units of 100 t. (rounded to the nearest 100)
4) Download the data. Check the data in the cycle data (payload, dumping time) to be correct.
11. Data clear

1) Press [MODE] switch for more than 2 seconds. The display flashes 'oCHE' (it means operator check
mode).
2) Press [MODE] switch. The display is 'd000' (it means machine ID).
3) Press [MODE] switch. The display is '_ _ YZ' ('Z' is flashed, YZ means lower 2 digits of year. 'YZ' for
2003 is '03').
4) Press [MODE] switch. The display is 'A.CLE' ('CLE' is flashed).
5) Press [CAL/CLR] switch for more than 2 seconds. The display is 'A.CLE' ('A.CLE' is flashed).
6) Press [CAL/CLR] switch for more than 2 seconds. The display is 'A.CLE' ('A.CLE is lighted up). All
clear of the cycle data and fault history will be started.
7) After all clear, the display becomes clock set.
8) Turn off engine.
32 HM400-2
HM400-2 33
© 2008 KOMATSU
All Rights Reserved
34 HM400-2
SEN00527-02

HM400-2

HM400-2 2001 and up

Sensors, switches ........................................................................................................................................... 2
KOMTRAX terminal system (if equipped) ..................................................................................................... 12
HM400-2 1
Sensors, switches
Accelerator sensor
Serial No.: 2001 – 2188
1. Pedal
2. Connector
Outline
Accelerator signal Idle validation signal
• This is installed under the operator’s cab. The • This is installed under the operator’s cab.
accelerator pedal and accelerator sensor are When the accelerator pedal is released, signal
connected by a link. When the accelerator pedal 2 (No. 5 pin) is connected to the ground; when
is depressed, the movement is passed through the accelerator pedal is depressed, signal 3
the link and rotates the shaft of the potentiome- (No. 6 pin) is connected to the ground.
ter inside the accelerator sensor. The engine controller then detects the condi-
As a result, the resistance changes. A fixed tion.
voltage is impressed between the No. 1 – 3 pins
of the potentiometer. A voltage signal corre-
sponding to the angle of the accelerator pedal is
sent from the No. 2 pin to the engine controller.
2 HM400-2
1. Pedal 3. Sensor
2. Connector
Function
• This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle val-
idation signal depending on the accelerator Output characteristics
pressing angle.
Accelerator signal
• Magnitude of the accelerator pedal displace-
ment being detected by the potentiometer inside
the sensor is output in variable voltage from No.
2 pin.
Idle validation signal

• The switch inside the sensor detects the accel-
erator pedal operation. As the accelerator pedal
is released, it outputs the signal being entered to
No. 5 pin from No. 4 pin. And as the accelerator
pedal is pressed, it outputs the signal being en-
tered to No. 6 pin from No. 4 pin.
HM400-2 3
Retarder oil temperature sensor
1. Thermistor
2. Plug
3. Wiring harness
4. Connector
Function
• The retarder oil temperature sensor is installed
on the retarder pipe. It converts a temperature
change into a change of thermistor resistance,
and transmits a signal to the T/M controller. The
T/M controller transmits the signal via the net-
work to the machine monitor panel, and the ma-
chine monitor panel displays a temperature
level. The temperature level displayed on the
monitor panel reaches a predetermined posi-
tion, the lamp flashes and the warning buzzer
sounds.
Steering oil temperature sensor
1. Sensor
2. Terminal
3. Connector
Function
• The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor por-
tion detects the temperature, and when the oil
temperature goes above the specified level, the
warning lamps lights up and a message is dis-
played on the character display of the monitor
panel.
4 HM400-2
Fuel level sensor
1. Connector
2. Wire resistor
3. Arm
4. Float
Function
• The fuel sensor is installed to the side face of the
fuel tank. The float moves up and down accord-
ing to the fuel level. This movement of the float
is transmitted by the arm and actuates a variable
resistance. This sends a signal to the monitor
panel to indicate the remaining fuel level. When
the display of the monitor panel reaches a cer-
tain level, a warning lamp flashes.
HM400-2 5
Tilt sensor
1. Magnetic resistance particle

2. Leaf spring
3. Damper oil
Function
• The tilt sensor is installed to the rear of the chas-
sis. A magnet supported by a leaf spring is in-
stalled to a case charged with damper oil. It uses
the position in relation to the magnetic resis-
tance element to detect the tilt angle of the chas-
sis.
The magnet is supported by the leaf spring, so
it does not detect the front-to-rear tilt of the
chassis.
6 HM400-2
Air cleaner clogging sensor
1. Indicator
2. Spring
3. Adapter
Function
• The air cleaner clogging sensor is installed to
the outward port of the air cleaner. If the air
cleaner becomes clogged and reaches the set
pressure (negative pressure), the maintenance
warning lamp lights up to warn of the abnormal-
ity.
HM400-2 7
Hydraulic oil level sensor
1. Connector
2. Float
3. Switch
Function
• The hydraulic oil level sensor is installed to the
side face of the hydraulic tank. When the oil
goes below the specified level, the float goes
down, the switch is turned OFF, and the mainte-
nance caution lamp lights up to warn of the ab-
normality.
8 HM400-2
Body positioner sensor
1. Bearing
2. Brush Ass'y
3. Connector
Function
• The body position sensor is installed to the rear
of the chassis. When the angle of the dump
body changes, the shaft rotates through the link
installed to the dump body, and the dump body
angle is detected.
HM400-2 9
Pressure sensor (for payload meter) Inclinometer (for payload meter)

• The pressure sensor is installed at the bottom • To carry out compensation on slopes, the inli-
end of the suspension cylinder for front right/left nometer measures the longitudinal tilt angle of
suspension cylinders and rear right/left suspen- the chassis. It is installed at the real frame.
sion cylinders and acts to measure the pressure
at the cylinder bottom.
• When replacing pressure sensor (1), leave the
valve (2) installed to the suspension and remove
only pressure sensor (1).
• When removing or installing pressure sensor
(1), be careful not to let valve (2) rotate. Valve (2)
include a check valve and prevents the pressure
from going down.
• The out put characteristics of the inclinometer

are as shown in the diagram.
• The out put characteristics of the sensor are as

shown in the diagram.
10 HM400-2
Body sensor (for payload meter)

• Body sensor is a proximity sensor which detects
the body to be seated or not.
• The gap between the sensor and the plate has
to be maintained within 3.5 to 6.3mm.
Articulate angle sensor (for payload

meter)
• Articulate angle sensor detects the articulate an-
gle between the front and rear frame.
HM400-2 11
KOMTRAX terminal system (if equipped)
• The KOMTRAX terminal transmits various kinds

of machine information wirelessly. Persons to
operate the KOMTRAX can refer to the informa-
tion at office to provide various kinds of services
for customers.
a To provide the services, you need to make

an arrangement for starting the KOMTRAX
terminal service separately.
Information transmittable from KOMTRAX termi-

nal system includes the following.
1. Travel history
2. Service meter
3. Position information
4. Error history
and others.
12 HM400-2
KOMTRAX communication modem

TC300
1. DRC connector (40 poles) connecting part Outline

2. (Not connected) • The KOMTRAX terminal can obtain various
3. GPS antenna connector connecting part kinds of machine information from network sig-
4. Orbcomm nals or input signals in the machine, and trans-
mit the information via the communication
antenna. The terminal is equipped with a CPU
(central processing unit), and has wireless com-
munication and GPS functions as well.
• The terminal is provided with a LED lamp and a
7-segment display lamp as a display unit. The
display unit is used for inspection and mainte-
nance.

• DRC connector
Pin No. Signal name Input/output Pin No. Signal name Input/output
1 232C (OCH) control signal Input 21 Inspection mode Input
2 232C (OCH) control signal Output 22 Inspection mode Input
3 232C (OCH) control signal Input 23 232C (OCH) control signal Input
4 232C (OCH) receiving Input 24 (If equipped) Input
5 232C (OCH) transmitting Output 25 (If equipped) Input
6 CAN shield GND — 26 (If equipped) Input
7 CAN signal (L) Input/output 27 C terminal input (Hi side) Input
8 CAN signal (H) Input/output 28 R terminal input Input
9 S-NET shield GND — 29 EXGND —
10 S-NET signal Input/output 30 (If equipped) Output
11 232C (OCH) shield GND — 31 (If equipped) (5V MAX) Input
12 Writing signal Input 32 (If equipped) (5V MAX) Input
13. 232C (ICH) receiving Input 33 232C (OCH) control signal Input
14. 232C (ICH) transmitting Output 34 (If equipped) Input
15. 232C (OCH) control signal Output 35 (If equipped) Output
16. (If equipped) Input 36 ACC Input Input
17. (If equipped) Input 37 Power supply GND (if equipped) —
18. (If equipped) Output 38 Power supply GND (if equipped) —
19. (If equipped) Output 39 Permanent power supply (12V/24V) Input
20. Relay output Output 40 Permanent power supply (12V/24V) Input
*: Never connect to NC or malfunctions or failure will occur. *: Never connect to NC or malfunctions or failure will occur.
HM400-2 13
© 2008 KOMATSU
All Rights Reserved
14 HM400-2
SEN00915-02
HM400-2

HM400-2 2001 and up
20 Standard value table 1

Standard service value table
Standard value table for engine ...................................................................................................................... 2
Standard value table for chassis ..................................................................................................................... 3
HM400-2 1
SEN00915-02 20 Standard value table
Standard value table for engine 1
Engine SAA6D140E-5
Classi- Standard value for

Check item Measurement conditions Unit Permissible value
fication new machine
2,200 (+50/0) 2,200 (+50/0)
High power High power
High idle rpm
• Coolant temperature: 2,000 (+50/0) 2,000 (+50/0)
Engine speed (Economy) (Economy)
Within operating range
Low idle rpm 725 ± 25 725 ± 25
Rated rpm rpm 2,000 2,000
• Coolant temperature: Within operating
range
Intake air pressure kPa Min. 160 136
(boost pressure) • Power train oil temperature: Within oper- {mmHg} {Min. 1,200} {1,020}
ating range
• When torque converter is stalling
Exhaust temperature • Whole speed range (Ambient tempera- °C Max. 650 700
ture: 20 °C)
%
At sudden Max. 25 35
(Bosch
• Coolant temperature: acceleration (Max. 2.5) (3.5)
Exhaust gas color index)
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance • At cold
Exhaust valve mm 0.57 —
Compression MPa Min. 4.1 2.8
Compression • Engine oil temperature: pressure {kg/cm²} {Min. 42} {29}
pressure 40 – 60 °C
Engine
Engine speed rpm 200 – 250 200 – 250

• Coolant temperature: Within operating
range
kPa Max. 2.94 3.92
Blow-by pressure • Power train oil temperature: Within oper- {mmH2O} {Max. 300} {400}
ating range
• When torque converter is stalling
• SAE0W30E0S,
SAE5W40E0S, Torque MPa Min. 0.34 0.21
SAE10W30DH, converter stall {kg/cm²} {Min. 3.5} {2.1}
Engine oil pressure SAE15W40DH,
SAE30DH oil MPa Min. 0.10 0.08
• Engine oil temperature: Low idle {kg/cm²} {Min. 1.0} {0.8}
Min 80 °C
Oil temperature • Whole speed range (Inside oil pan) °C 90 – 110 120
• Between fan pulley and tension pulley 19 – 21
15 – 17
Fan belt tension • Deflection when pressed with finger force mm (When re-ten-
(When new)
of 98N {10kg} sioned)
• Between water pump pulley and alterna-
Alternator belt tor pulley
mm 13 – 16 13 – 16
tension • Deflection when pressed with finger force
of 98N {10kg}
• Between compressor pulley and drive
Air conditioner com- pulley
mm Approx.10 Approx.10
pressor belt tension • Deflection when pressed with finger force
of 59N {6kg}
2 HM400-2
Standard value table for chassis 1

Classi- Standard value

fication for new machine
Starting to N 29.4 ± 4.9 29.4 ± 4.9
Accelerator pedal
• 150 mm from pedal depress {kg} {3.0 ± 0.5} {3.0 ± 0.5}

Operating effort
fulcrum N 58.8 ± 4.9 58.8 ± 4.9
Full
{kg} {6.0 ± 0.5} {6.0 ± 0.5}
Stroke • 150mm from pedal fulcrum mm 45 ± 5 45 ± 5
Torque converter • Coolant temperature:

lockup activation Within operating range rpm 1,200 ± 50 1,200 ± 50
speed
• Torque converter oil
Torque converter temperature: Brake ON rpm 1,200 ± 50 —
lockup deactivation Within operating range
speed • Hydraulic oil tempera- BrakeOFF rpm 1,200 ± 50 —
Torque converter stall ture: 45 – 55 °C
• Engine: High idle rpm 1,832 ± 100 —
speed
F1 – F4: F1 – F4:
Engine
Transmission shift up • Coolant temperature: 1,950 ± 50 1,950 ± 50

rpm
speed Within operating range F4 – F6: F4 – F6:
Engine speed
• Torque converter oil Normal 2,000 ± 50 2,000 ± 50

temperature: mode F3 – F2: F3 – F2:
Transmission shift Within operating range 1,200 ± 50 1,200 ± 50
rpm
down speed • Hydraulic oil tempera- Other than above Other than above
ture: 45 – 55 °C 1,250 ± 50 1,250 ± 50
Transmission shift up • Normal mode: Engine:
High idle rpm 2,200 ± 50 2,200 ± 50
speed Brake
• Brake mode:
Transmission shift mode
Accelerator OFF rpm 1,360 ± 50 1,360 ± 50
down speed
condition or brake ON
Transmission down condition
rpm 1,550 ± 50 1,550 ± 50
shift inhibit speed
Over run prevention
rpm 2,450 ± 10 2,450 ± 10
activation speed
Over run prevention
rpm 2,150 ± 10 2,150 ± 10
deactivation speed
N 21.6 ± 3.9 Max. 19.6
Gear shift
Operating effort
• Center of lever grip {kg} {2.2 ± 0.4} {Max. 2.0}
lever
• Between each position

Stroke mm 24.5 ± 1 24.5 ± 2
• Torque converter oil MPa 2.36 ± 0.20 2.36 ± 0.20

Low idle
Power train main temperature: {kg/cm²} {24.1 ± 2.0} {24.1 ± 2.0}
Power train
relief pressure Within operating range MPa 2.64 ± 0.20 2.64 ± 0.20
High idle
• Shift lever: N {kg/cm²} {26.9 ± 2.0} {26.9 ± 2.0}
Oil pressure
Torque converter inlet MPa 0.91 ± 0.10 0.91 ± 0.10

pressure {kg/cm²} {9.3 ± 1.0} {9.3 ± 1.0}
Torque converter • Torque converter oil temperature: MPa 0.59 ± 0.10 0.59 ± 0.10
outlet pressure Within operating range {kg/cm²} {6.0 ± 1.0} {6.0 ± 1.0}
Torque converter • Engine: High idle
MPa 1.81 ± 0.20 1.81 ± 0.20
lock-up clutch
{kg/cm²} {18.5 ± 2.0} {18.5 ± 2.0}
pressure
HM400-2 3

Transmission Lo MPa 2.55 ± 0.15 2.55 ± 0.15
clutch pressure {kg/cm²} {26, 0 ± 1.5} {26.0 ± 1.5}
Transmission Hi MPa 2.55 ± 0.15 2.55 ± 0.15
clutch pressure {kg/cm²} {26.0 ± 1.5} {26.0 ± 1.5}
Transmission 1st MPa 2.55 ± 0.15 2.55 ± 0.15
clutch pressure {kg/cm²} {26.0 ± 1.5} {26.0 ± 1.5}
Transmission 2nd MPa 2.55 ± 0.15 2.55 ± 0.15
Oil pressure
clutch pressure • Torque converter oil temperature: {kg/cm²} {26.0 ± 1.5} {26.0 ± 1.5}
Transmission 3rd Within operating range MPa 2.45 ± 0.15 2.45 ± 0.15
clutch pressure • Engine: High idle {kg/cm²} {25.0 ± 1.5} {25.0 ± 1.5}
Transmission R clutch MPa 2.55 ± 0.15 2.55 ± 0.15
pressure {kg/cm²} {26.0 ± 1.5} {26.0 ± 1.5}
Inter-axle differential MPa 2.45 ± 0.15 2.45 ± 0.15
lock clutch pressure {kg/cm²} {25.0 ± 1.5} {25.0 ± 1.5}
Transmission lubricat-
MPa 0.20 ± 0.049 0.20 ± 0.049
ing oil pressure
{kg/cm²} {2.0 ± 0.5} {2.0 ± 0.5}
Power train
(For reference)
6.9 ± 10%
F1 km/h 6.9 ± 10%
(6.5)
11.1 ± 10%
F2 km/h 11.1 ± 10%
(10.0)
• Level ground
17.1 ± 5%
F3 • Coolant temperature: km/h 17.1 ± 5%
(15.2)
Traveling speed
• Torque converter oil temperature: 26.1 ± 5%

F4 km/h 26.1 ± 5%
Within operating range (23.2)
• Engine: High idle 39.6 ± 5%
F5 • Power mode: km/h 39.6 ± 5%
(35.5)
High power (economy)
58.5 ± 5%
F6 • Dump body: unloaded km/h 58.5 ± 5%
(50.5)
• Traveling resistance: 3.3 %
7.4 ± 10%
R1 km/h 7.4 ± 10%
(6.6)
17.5 ± 5%
R2 km/h 17.5 ± 5%
(15.6)
• Standard tire: 29.5 – R25 MPa 0.372 0.372
Tire inflation pressure
• Dump body: Unloaded {kg/cm²} {3.8} {3.8}
• Torque converter oil temperature: MPa 2.45 ± 0.25 2.45 ± 0.25
Front differential within operating range {kg/cm²} {25 ± 2.5} {25 ± 2.5}
Differential lock
• Differential oil temperature:

Oil pressure
Min. 20°C
MPa 2.45 ± 0.25 2.45 ± 0.25
Center differential • Engine: High idle {kg/cm²} {25 ± 2.5} {25 ± 2.5}
• Left and right differential lockup
switch: ON
MPa 2.45 ± 0.25 2.45 ± 0.25
Rear differential • Left and right differential lockup
pedal: Depressed {kg/cm²} {25 ± 2.5} {25 ± 2.5}
For front 4.4 ± 0.15 4.4 ± 0.15

Gas pressure
Accumulator
Nitorogen brake {45 ± 15} {45 ± 15}

• Gas temperature (atmosphere MPa
gas pres-
For rear temperature): 20 ± 5 °C {kg/cm²}
sure 4.4 ± 0.15 4.4 ± 0.15
parking
{45 ± 15} {45 ± 15}
brake
4 HM400-2

N Max. 294 Max. 294
Operating effort
{kg} {Max. 30} {Max. 30}
Brake
pedal
• 150 mm from pedal fulcrum

(Pedal end) 44.5 ± 5 44.5 ± 5
Stroke mm
(66.5 ± 5) (66.5 ± 5)
N 5.9 – 9.8 3.0 – 14.7
Retarder
Operating effort
lever
• 10 mm from lever end {kg} {0.6 – 1.0} {0.3 – 1.5}

Stroke Deg. 0 – 78 ± 1 0 – 78 ± 2
Charge valve cut-in • Wheel brake actuating pressure: MPa 11.77 (+0.49/0) 11.77 (+0.49/0)
pressure Actuating pressure when brake is {kg/cm²} {120 (+5.0/0)} {120 (+5.0/0)}
Charge valve cut-out operated for the first time after MPa 20.59 ± 0.98 20.59 ± 0.98
pressure engine is stopped {kg/cm²} {210 ± 10} {210 ± 10}
Oil pressure
• Drop in wheel brake actuating

Wheel brake MPa 4.9 ± 0.49 4.9 ± 0.49
pressure: Drop in pressure 5 min-
actuating pressure {kg/cm²} {50 ± 5} {50 ± 5}
utes after specified oil pressure
Drop in wheel brake (4.9 MPa {50 kg/cm²}) is applied MPa Max. 0.49 Max. 0.49
actuating pressure • Parking brake release pressure: {kg/cm²} {Max. 5} {Max. 5)
Parking brake release Pressure when parking brake MPa 3.92 ± 0.39 3.92 ± 0.39
Brake
pressure switch is ON at high idle {kg/cm²} {40 ± 4} {40 ± 4}

Service brake brak-
• Engine: High idle rpm 1,400 1,400
ing performance
• Shift lever: D
Wheel brake
Retarder brake
• Torque converter stall speed rpm 1,090 1,090
braking performance
• Flat dry road
Service brake brak-
• 36.5 t loaded m Max. 22.3 Max. 22.3
ing distance
• Traveling speed: 32km/h
• Flat dry road
Parking brake
Braking performance • Shift lever: D rpm 1,400 1,400

• Torque converter stall speed
• 36.5 t loaded
Braking slope angle % Min. 25 Min. 25
• Slope angle (sin )
• 9 ± 1% traveling downhill
Emergency brake braking
• 36.5 t loaded m Max. 52.1 Max. 52.1
distance
• Traveling speed: 25 ± 2 km/h
• Engine: Low idle N Max. 29.4 Max. 35.3

Operating effort
• Dump body: Unloaded {kg} {Max. 3.0} {Max. 3.6}
• Shift lever: N (Stopped) 20 – 50 20 – 50
Steering wheel
Play • On steering wheel circumference mm (Engine stopped: (Engine stopped:

• Operating effort: When operating Max. 150) Max. 150)
at 10 rpm (steering wheel turning
Steering
Rotation speed speed) Rotation 4.1 ± 0.5 4.1 ± 0.5

• Play: Until tires start to move
• Rotation speed: Lock to lock
Turning time Sec. Max. 7 Max. 8
• Turning time: Lock to lock
• Hydraulic oil temperature:

MPa 20.59 (+0.98/0) 20.59 (+0.98/0)
Steering relief oil pressure 45 – 55 °C
{kg/cm²} {210 (+10/0)} {210 (+10/0)}
• Engine: High idle
HM400-2 5

• On a level road surface
• Dump Body: Unloaded
Installation length mm 153 ± 10 153 ± 10
• Refer to Fig. 1 for inspection posi-
Front
tion (dimensions a)
Suspension cylinder
• On a level road surface MPa 4.31 ± 0.15 4.31 ± 0.15

Pressure
• Dump body: unloaded {kg/cm²} {44.0 ± 1.5} {44.0 ± 1.5}
• On a level road surface
• Dump body: Unloaded
Installation length mm 96 ± 5 96 ± 5
• Refer to Fig. 2 for inspection point
Rear
(dimension a)
• On a level road surface MPpa 1.18 ± 0.15 1.18 ± 0.15
Pressure
• Dump body: Unloaded {kg/cm²} {12.0 ± 1.5} {12.0 ± 1.5}
Hold o N Max. 29.4 Max. 35.3
Raise {kg} {Max. 3.0} {Max. 3.6}
Raise o N
Must return smoothly
Hold {kg}
Hold o N Max. 29.4 Max. 35.3
• Engine stopped Float {kg} {Max. 3.0} {Max. 3.6}
Dump lever operating effort
• Center of grip Float o N Max. 29.4 Max. 35.3
Hold {kg} {Max. 3.0} {Max. 3.6}
Float o N Max. 29.4 Max. 35.3
Lower {kg} {Max. 3.0} {Max. 3.6}
Lower o N
Must return smoothly
Float {kg}

Lifting time Second 12 ± 1.5 12 ± 1.5
45 – 55 °C
Dump
Lowering time • Lowering time when operating Second 12 ± 1.5 12 ± 1.5

float
Body • Hydraulic oil temperature:

45 – 55 °C
• Hold at point where No.2 cylinder
Hydraulic drift is extended 100 mm. mm Max. 85 Max. 170
• Engine stopped
• Downward movement at the end
of dump body over 5 minutes
MPa 20.59 (+0.98/0) 20.59 (+0.98/0)
Dump relief oil pressure 45 – 55 °C
{kg/cm²} {210 (+10/0)} {210 (+10/0)}
• Hydraulic oil tempera- High idle MPa 3.4 ± 0.49 3.4 ± 0.49
ture: 45 – 55 °C {kg/cm²} {35 ± 5} {35 ± 5}
Dump pilot relief pressure
• Values at low idle are MPa 2.6 ± 0.49 2.6 ± 0.49
Low idle
for reference {kg/cm²} {27 ± 5} {27 ± 5}
6 HM400-2
Inspection procedure for performance test
Fig 1: Front suspension cylinder rod installation length (a)
Fig 2: Rear suspension cylinder rod installation length (b)
HM400-2 7

© 2008 KOMATSU
All Rights Reserved
8 HM400-2
SEN00916-03

HM400-2

HM400-2 2001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 7
Testing intake air pressure (boost pressure) ................................................................................................... 8
Testing exhaust temperature........................................................................................................................... 9
Testing exhaust gas color ............................................................................................................................. 10
Adjusting valve clearance ..............................................................................................................................11
Testing compression pressure ...................................................................................................................... 12
Testing blow-by pressure .............................................................................................................................. 14
Testing engine oil pressure ........................................................................................................................... 15
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 16
Handling of fuel system devices ................................................................................................................... 17
Releasing residual pressure from fuel system .............................................................................................. 17
Testing fuel pressure..................................................................................................................................... 18
Testing fuel return and leakage amount........................................................................................................ 19
Bleeding air from fuel circuit.......................................................................................................................... 22
Testing the fuel circuit for leakage................................................................................................................. 24
HM400-2 1
SEN00916-03 30 Testing and adjusting
Testing and adjusting fan belt tension ........................................................................................................... 25

Testing and adjusting alternator belt tension................................................................................................. 26
Testing and adjusting air conditioner compressor belt tension...................................................................... 27
2 HM400-2
Tools for testing, adjusting, and troubleshooting 1

Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Testing air boost pressure -101 – 200 kPa
A 799-201-2202 Boost gauge kit 1
(boost pressure) {-760 – 1,500 mmHg}
Testing exhaust tempera- Digital temperature
B 799-101-1502 1 -99. 9 – 1,299 °C
ture gauge
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color C Commercial Bosch index: 0 – 9
2 Smoke meter 1
item
Commercial
Adjusting valve clearance D Clearance gauge 1 Intake: 0.35 mm, Exhaust: 0.57 mm
item
1 795-502-1590 Compression gauge 1 0 – 7 MPa {0 – 70 kg/cm²}
Testing compression
E 795-471-1330 Adapter 1
pressure 2 For 140E-5 engine
6261-71-6150 Gasket 1
Testing blow-by pressure F 799-201-1504 Blow-by checker 1 0 - 5kPa {0 - 500mmH2O}
Pressure gauge:
Testing engine oil pressure 799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
• 1 {25, 60, 400, 600 kg/cm²}
Testing EGR valve and G Digital type hydraulic Pressure gage:
790-261-1204 1
bypass valve drive oil pres- tester 60 MPa {600 kg/cm²}
sure Pressure gauge:
2 799-401-2320 Hydraulic tester 1
1 MPa {10kg/cm²}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40,60 MPa
1 {25, 60, 400, 600kg/cm²}
Pressure gage:
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure H 60 MPa {600kg/cm²}
Pressure gauge:
1 MPa {10kg/cm²}
795-471-1450 Adapter 1
3 8 × 1.25mm o R1/8
07005-00812 Gasket 1
Method of tilting cab up I 792-454-1100 Pump assembly 1 For tilt cylinder
1 6151-51-8490 Spacer 1 Inner diameter: 14mm
2 6206-71-1770 Joint 1 Inner diameter of joint part: 10mm
Commercially
3 Hose 1 ø5 mm × 2 – 3 m
available
Testing fuel return and leak- Commercially
J 4 Hose 1 ø15 mm × 2 – 3 m
age amount available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm²}
Testing power train oil
K Pressure gage:
pressure 790-261-1204 Digital hydraulic tester 1
60 MPa {600kg/cm²}
Pressure gauge:
1 MPa {10kg/cm²}
HM400-2 3
Sym-
Q'ty
bol
Pressure gauge:
Testing and adjusting differ- {25, 60, 400, 600 kg/cm²}
L
ential lockup oil pressure
Pressure gage:
60 MPa {600 kg/cm²}
Pressure gauge:
Testing and adjusting brake 1 {25, 60, 400, 600 kg/cm²}
M
oil pressure Pressure gauge:
60 MPa {600 kg/cm²}
2 793-520-1805 Brake test kit 1 19. 6 Mpa {200 kg/cm²}
Pressure gauge:
Testing and adjusting steer- {25, 60, 400, 600 kg/cm²}
N
ing circuit oil pressure
Pressure gage:
60 MPa {600 kg/cm²}
1 792-610-1000 Suspension tool 1
2 792-610-1130 • Pump 1
3 792-610-1110 • Hose 1
4 792-610-2200 • Joint 1
P2 – P6: Pump assembly
5 07020-21732 • Fitting 1
(Kit part No: 792-610-1100)
6 792-610-1140 • Joint 1
Testing and adjusting sus- P7 – P13: Charging tool assembly
P 7 792-610-1250 • Valve 1
pension cylinder (Kit part No: 792-610-1200)
8 792-610-1260 • Nipple 1
9 792-610-1270 • Hose 1
10 792-610-1640 • Joint 1
11 792-610-1400 • Regulator 1
12 792-610-1430 • Gauge 1 25 MPa {250 kg/cm²}
13 792-610-1440 • Gauge 1 1 MPa {100 kg/cm²}
Pressure gauge:
Testing and adjusting dump {25, 60, 400, 600 kg/cm²}
Q
circuit oil pressure
Pressure gauge:
60 MPa {600kg/cm²}
1 792-610-1700 Gas charge tool 1
792-610-1310 Nipple (For Russia) 1 GOST
Testing of accumulator nitro- 792-610-1320 Nipple (For USA) 1 GCA No.351
gen gas pressure and pro-
cedure for charging R 792-610-1330 Nipple (For USA) 1 ASA B-571-1965
accumulator with nitrogen 2 DIN 477-1963
gas 792-610-1350 Nipple (For Germany) 1 NEN 3268-1966
SIS-SMS 2235/2238
792-610-1360 Nipple (For UK) 1 BS 341 Part 1-1962
Testing water temperature Digital temperature
– 799-101-1502 1 -99. 9 – 1,299 °C
and oil temperature gauge
Testing operation effort and – 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
pedal effort – 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Testing stroke and hydrau- Commercially
– Scale 1
lic drift available
4 HM400-2
Sym-
Q'ty
bol
Testing work equipment Commercially
– Stopwatch 1
speed available
Testing voltage and resis- Commercially
– Tester 1
tance available
799-601-4101
or T-adapter kit 1
799-601-4201
799-601-4130 • T-adapter 1 For Ne sensor
799-601-4330 • Socket 1 For G (Bkup) sensor
799-601-4240 • Socket 1 For Atomospheric sensor
799-601-4250 • Socket 1 For boost pressure sensor
799-601-9420 • T-adapter 1 For common rail pressure sensor
799-601-4150 • T-adapter 1 For oil pressure sensor
For boost (intake) temperature
795-799-5540 • Socket 1
sensor
Engine related controller, For coolant temperature sensor
795-799-5530 • Socket 1
sensor and actuator diagno- – For fuel temperature sensor
sis 799-601-9430 • Socket 1 For supply pump PCV
799-601-9020 • T-adapter 1 For injector, RES for supply pump*
799-601-4260 • T-adapter 1 For controller (4-pole)
For controller (50-pole)
799-601-4211 • T-adapter 1
(799-601-4101 only)
For controller (60-pole)
799-601-4220 • T-adapter 1
(799-601-4101 only)
For 60-pole
799-601-4350 • T-adapter 1
(799-601-4101 only)
799-601-9030 • T-adapter 1 DT3 For network pull up resistor*
DT12 For inter mediate connector
799-601-9120 • T-adapter 1
to injectors*
799-601-9000
or T-adapter kit 1 For HD30 adapter
Wiring harness diagnosis of 799-601-9100
machine 799-601-9320 • T-box 1 For HD • DT
–
(inter mediate connector 799-601-9220 • For HD30-18 1 14P
with operator cab)
799-601-9250 • For HD30-24 adapter 1 9P
799-601-9290 • For HD30-24 adapter 1 31P
799-601-7000
or
799-601-7100
or T-adapter kit 1 For X, SWP, M, S adapter
799-601-7400
Wiring harness diagnosis of or
machine 799-601-8000
–
(controller, sensor, valve, 799-601-7040 • For X adapter 1 X4P
light diagnosis) SW6P
799-601-7050 • For SWP adapter 1
(799-601-8000 is not include)
SW8P
799-601-7060 • For SWP adapter 1
(799-601-8000 is not include)
799-601-7090 • For M adapter 1 M2P
*: Included in 799-601-9000 and 799-601-9200
HM400-2 5
Sym-
Q'ty
bol
799-601-7110 • For M adapter 1 M3P
799-601-7120 • For M adapter 1 M4P
799-601-7130 • For M adapter 1 M6P
799-601-7140 • For S adapter 1 S8P
799-601-7180 • For AMP040 adapter 1 A8P (799-601-7400 only)
799-601-7310 For SWP adapter 1 SW12P
799-601-7320 For SWP adapter 1 SW16P
799-601-7360 For relay adapter 1 REL-5P
799-601-7370 For relay adapter 1 REL-6P
799-601-7500 T-adapter kit 1 For 070 adapter
799-601-7520 • For 070 adapter 1 07-12P
799-601-7540 • For 070 adapter 1 07-18P
799-601-7550 • For 070 adapter 1 07-20P
799-601-9000
or T-adapter kit 1 For DT adapter
799-601-9200
799-601-9020 • For DT adapter 1 DT2P*%
Wiring harness diagnosis of
machine 799-601-9030 • For DT adapter 1 DT3P
–
(controller, sensor, valve, 799-601-9040 • For DT adapter 1 DT4P*%
light diagnosis)
799-601-9050 • For DT adapter 1 DT6P
• For DT adapter
799-601-9060 1 DT8PGR
(Gray)
• For DT adapter
799-601-9070 1 DT8PB
(Black)
• For DT adapter
799-601-9080 1 DT8PG
(Green)
• For DT adapter
799-601-9110 1 DT12PGR
(Gray)
• For DT adapter
799-601-9120 1 DT12PB
(Black)
• For DT adapter
799-601-9130 1 DT12PG
(Green)
• For DT adapter
799-601-9140 1 DT12P
(Brown)
799-601-9300 T-adapter kit 1 For DRC adapter
799-601-9350 • For DRC adapter 1 DRC-40
799-601-9360 • For DRC adapter 1 DRC-24
*: Included in 799-601-9000 and 799-601-9200

*%: Included in 799-601-4101 and 799-601-4201
6 HM400-2
Measuring engine speed 1

k Stop the machine on the level ground, turn
the parking brake switch ON, and set
chocks to the tires.
1. Measuring of low idle speed and high idle

speed
1) Turn the starting switch ON and set the
machine monitor in the real-time monitor-
ing function (REAL-TIME MONITOR) of
the service mode.
q Monitoring system:
MONITOR PANEL
q Monitoring code:
01001 (ENG SPEED)
a For the operation method, see Test-
ing and adjusting, "Special functions
of machine monitor".
2) Start the engine and raise the temperature

of torque converter oil and hydraulic oil.
q Torque converter oil temperature:
60 – 80 °C
q Hydraulic oil temperature: 45 – 55 °C
3) Check each rotation speed when the
engine is in low idle and high idle.
2. Measuring of torque converter stall speed

a See "Testing of torque converter stall
speed".
HM400-2 7
Testing intake air pressure (boost a If any oil is left in the hose, the gauge does
not move. Accordingly, be sure to drain
pressure) 1 the oil.
a Testing instruments of intake air pressure
(boost pressure) 5. Turn the parking brake switch ON, depress the
brake pedal, and then set the gear shift lever to
Symbol Part number Part name
the D position.
A 799-201-2202 Boost gauge kit k If the gearshift lever is operated to any
position other than the D position, the
k Stop the machine on the level ground, turn machine may move off even if the brake is
the parking brake switch ON, and set being depressed, so always test at the D
chocks to the tires. position.
k When installing and removing the testing
instrument, take care not to touch a hot part 6. Depress the accelerator pedal gradually and
of the engine. check intake air pressure while the engine is
running at high idle and the torque converter is
1. Open the engine hood. stalling.
k There is danger of damage to the internal
2. Remove intake air pressure inspection plug (1) parts of the transmission, so never operate
from aftercooler piping. the gear shift lever to any position other
than the D position during the stall opera-
tion.
a After completing the test, lower the engine
speed to low idle, then return the gearshift
lever to the N position.
3. Install nipple [1] of boost gauge kit (A), and

connect gauge [2].
7. When the testing is completed, remove the

instruments and set to the original condition.
4. Run the engine at medium or higher speed and

drain the oil from the inspection hose.
a Insert the joint of the gauge and hose half-
way, and open the self-seal on the hose
side repeatedly, then the oil is drained.
a If Pm kit (A) is available, the oil draining
coupling (790-261-1130) in it may be
used.
8 HM400-2
Testing exhaust temperature 1 2) Turn the parking brake switch ON, de-
press the brake pedal, and then set the
a Testing instrument for exhaust temperature gear shift lever to the D position.
Symbol Part number Part name k If the gearshift lever is operated to
B 799-101-1502 Digital temperature gauge any position other than the D posi-
tion, the machine may move off
k Stop the machine on the level ground, turn even if the brake is being
the parking brake switch ON, and set depressed, so always check at the
chocks to the tires. D position.
k Install and remove the testing instrument 3) Depress the accelerator pedal gradually,
after the exhaust manifold is cooled. run the engine at high idle and stall the
torque converter. At the same time, oper-
1. Open the engine hood and remove the turbo- ate the dump lever to the LOWER position
charger heat insulation cover. and relieve the oil pressure (full stall).
2. Remove exhaust temperature testing plug (1), a Continue until the exhaust temperature
which is in the middle of exhaust manifold. reaches the standard value of 650 °C.
k There is danger of damage to the inter-
nal parts of the transmission, so never
operate the gear shift lever to any posi-
tion other than the D position during
the stall operation.
4) When the temperature stabilizes at near
the target temperature, return the dump
lever to NEUTRAL and check the tempera-
ture with only the torque converter stalled.
a The exhaust temperature will start to
go down from the full stall condition,
so measure the temperature when it
stabilizes.
a If the exhaust temperature does not
3. Install sensor [1] of digital temperature gauge
go down but rises, make the set tem-
(B) and connect it to meter [2].
perature at full stall higher.
a Clamp the wiring harness of the digital
a After completing the test, lower the
thermometer so that it does not touch a
engine speed to low idle, then return
hot part during measurement.
the gearshift lever to the N position.
4. Procedure for testing while torque converter is

5. Procedure for testing the maximum tempera-
stalling:
ture during actual operation
a To prevent the torque converter from over-
Operate the machine actually and measure the
heating, use the full stall (torque converter
maximum exhaust temperature.
stall + hydraulic relief) to stabilize the
a Use the PEAK mode of the digital ther-
exhaust temperature, then stall only the
mometer.
torque converter and carry out the test.
1) Start the engine and raise the temperature 6. When the testing is completed, remove the
of the engine to the operating range. instruments and set to the original condition.
HM400-2 9
Testing exhaust gas color 1

a Testing instrument for exhaust gas color
1 799-201-9001 Handy smoke checker
C Commercially
2 Smoke meter
available

k When installing and removing the testing
instrument, take care not to touch a hot
2) Connect the probe hose, receptacle of the
part.
accelerator switch, and air hose to smoke
a If an air source and a electric power source are
meter C2.
not available in the field, use handy smoke
a Restrict the supplied air pressure
checker C1. When recording official data, etc.,
below 1.5 MPa {15 kg/cm²}.
use smoke meter C2.
3) Connect the power cable to a receptacle
of power source.
1. Testing with handy smoke checker C1
a Before connecting the cable, check
1) Attach a sheet of filter paper to handy
that the power switch of the smoke
smoke checker C1.
meter is turned off.
2) Insert the exhaust gas intake pipe in
4) Loosen the cap nut of the suction pump
exhaust pipe (1).
and fit the filter paper.
3) Start the engine and raise the temperature a Fit the filter paper securely so that the
of the engine to the operating range. exhaust gas does not leak.
4) As increasing the engine speed rapidly or 5) Turn on the power switch of smoke meter
running it at high idle, operate the handle C2.
of handy smoke checker C1 so that the fil-
ter paper absorbs the exhaust gas.
6) Start the engine and raise the coolant tem-

perature of the engine to the operating
5) Remove the filter paper and compare it range.
with the attached scale to make a judg-
7) As increasing the engine speed rapidly or
ment.
running it at high idle, press the accelera-
6) When the testing is completed, remove tor pedal of smoke meter C2 and collect
the instruments and set to the original the exhaust gas with the filter paper.
condition.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
2. Testing with smoke meter C2 filter paper holder and read the indicated
1) Insert probe [1] of smoke meter C2 in the value.
outlet of exhaust pipe (1) and fix it to the 9) When the testing is completed, remove
exhaust pipe with a clip. the instruments and set to the original
condition.
10 HM400-2
Adjusting valve clearance 1 4. Loosen locknut (4) with adjustment screw (3)
fixed
a Adjusting instrument for valve clearance a After setting the No. 1 cylinder at the com-
Symbol Part number Part name pression top dead center, adjust valve
clearance of No. 1 cylinder.
Commercially
D Clearance gauge
available
5. To adjust the valve clearance, insert clearance
k
gauge D into clearance between rocker arm
Stop the machine on the level ground, turn
(5) and crosshead (6), and adjust the valve
clearance with adjustment screw (3).
a With the clearance gauge inserted, turn
the adjustment screw so that clearance
1. Open the engine hood. gauge can move with a light force.
a Valve clearance
2. Remove all cylinder head covers (1). Intake valve: 0.35 mm,
Exhaust valve: 0.57 mm
6. While holding adjustment screw (3), tighten

locknut (4).
3 Locknut:
45.1 – 51.0 Nm {4.6 – 5.2 kgm}
a After tightening the locknut, check the
valve clearance again.
3. Rotate the crankshaft forward, align of damper

"1.6TOP" stamp line (a) to pointer (2), and then
set the No.1 cylinder to the compression top
dead center.
a Crank the crankshaft at hexagonal part of
water pump drive shaft tip.
a At the compression top dead center, the
rocker arm of No. 1 cylinder can be moved
with hand by the distance of valve clear- 7. After finishing the adjustment of No. 1 cylinder,
ance. If rocker arm does not move, it is not rotate the crank shaft forward by 120°at one
at the compression top dead center, so time to align "TOP" stamp line of each cylinder
rotate it one more turn. number to pointer (2), and adjust the valve
clearance of each cylinder in the sequence of
the firing order
q Firing order: 1 – 5 – 3 – 6 – 2 – 4
8. After finishing adjustment, set to the original

condition.
3 Cylinder head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
HM400-2 11
Testing compression pressure 1

a Testing instruments for compression pressure
1 795-502-1590 Compression gauge
E 795-471-1330 Adapter
2
6261-71-6150 Gasket

a When testing the compression pressure, take
care not to burn yourself on the exhaust mani-
fold, muffler, etc. or get caught in a rotating 5. Install adaptor E2 to mounting hole of injector
part. and connect compression gauge E1.
a Be sure to install the gasket to the top of
1. Open the engine hood. the adapter.
a Fix the adapter with the holder for injector.
3 Holder mounting bolt:
2. Remove head cover (1) of cylinder which com-
58.8 – 73.5 Nm {6 – 7.5 kgm}
pression pressure is checked.
a Leakage can be prevented by applying a
little amount of engine oil to the fitting
faces of the adapter and gauge.
6. Install rocker arm assembly (2) and adjust

valve clearance.
3 Rocker arm assembly mounting bolts:
93 – 103 Nm {9.5 – 10.5 kgm}
a Refer to "Adjusting valve clearance".
3. Set cylinder to be tested at compression top

dead center and remove rocker arm assembly
(2).
a For the procedure of setting each cylinder
to the compression top dead center, see
"Adjusting valve clearance."
4. Disconnect the fuel high-pressure tube (3) and
injector harness, and remove injector (4) and
wiring harness.
7. Disconnect power supply connector EGC3 (5)
a To remove injector harness from injector,
of engine controller.
k Be sure to disconnect the connector.
disconnect the terminal in the injector side
and the bracket in the rocker housing side.
Otherwise, engine may start during the
(Loosen 2 terminal nuts alternately.)
testing and this may create a danger-
a Lead a wire under the fuel pipe which
ous condition.
k Cover the controller side and the har-
comes out sideways from the injector and
pull up the wire to remove injector (do not
ness side with a vinyl sheet, etc. to pre-
ply the upper part of the injector to remove
vent electric leakage and grounding
it).
fault.
12 HM400-2
3) Temporarily tighten sleeve nut (15) of fuel

high-pressure tube.
4) Tighten bolt (13).
3 Bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
5) Tighten sleeve nut (15).
3 Sleeve nut:
39.2 – 49Nm{4 – 5 kgm}
8. Turn the starting switch ON and set the monitor

panel in the real-time monitoring function
(REAL-TIME MONITOR) of the service mode.
q Monitoring system: MONITOR PANEL
q Monitoring code: 01001 (ENG SPEED)
a For the operation method, see Testing and
adjusting, "Special functions of machine
monitor". a Install the injector harness according to
the following procedure.
1) Install injector harness to rocker arm
housing, and fix it with the plate on the
connector side.
2) Fix intermediate clamp with clip.
3) Tighten the injector side nut.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
4) Tighten clamp and spacer with bolt.
3 Rocker arm assembly mounting
bolts:
93 – 103 Nm {9.5 –10.5 kgm}
a Adjust valve clearance referring to "Ad-

justing valve clearance".
9. Crank the engine with the starting motor and 3 Cylinder head cover mounting bolt:
check the compression pressure. 29.4 – 34.3 Nm {3.0 – 3. 5 kgm}
a Measure the pressure when the pointer of
the gauge is stabilized.
a When testing the compression pressure,
also check the engine speed and confirm
that it is within a range of test condition.
10. When the testing is completed, remove the

a Install the injector and the fuel high-pres-
sure tube according to the following proce-
dure.
a Before installing the injector, replace the
cooper gasket and O-ring with new ones.
1) Push injector (11) with hand and install
holder (12) temporarily.
2) Temporarily tighten bolt (13) and washer
(14)
2 Washer spherical surface section:
engine oil
HM400-2 13
Testing blow-by pressure 1

a Testing instrument for blow-by pressure
F 799-201-1504 Blow-by checker

1. Remove engine under cover (small).
2. Install nozzle [1] and hose [2] to blow-by hose

(1) and connect to gauge [3]. 6. When the testing is completed, remove the
3. Start the engine and raise the coolant tempera-

ture of the engine to the operating range.
4. Turn the parking brake switch ON, depress the

brake pedal and set the gear shift lever to the
D position.
k If the gearshift lever is operated to any
machine may move off even if the
brake is being depressed, so always
test at the D position.
5. Depress the accelerator pedal gradually and

check blow-by pressure while the engine is
running at high idle and the torque converter is
stalling.
a After completing the test, lower the engine
speed to low idle, then return the gearshift
lever to the N position.
14 HM400-2
Testing engine oil pressure 1 5. Test engine oil pressure at low idle and torque
converter stall.
a Testing instruments for engine oil pressure a For the operation method of torque con-
Symbol Part number Part name verter stall, see Testing and adjusting
"Testing blow-by pressure".
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester

1. Open the engine hood.
2. Remove engine oil pressure inspection plug

(1) located at the cylinder block.
6. When testing is completed, remove the instru-

ments and set to the original condition.
3. Install nipple [1] and nipple [2] of hydraulic

tester G1 and connect to hydraulic tester G2.
a Since plug hole size is R1/4, quick nipple
(799-101-5201) can be used instead of
nipple [1] and [2].
4. Start the engine and raise the coolant tempera-

ture of the engine to the operating range.
HM400-2 15
Testing EGR valve and bypass 3. Connect hydraulic tester [2] and [3] (Compo-
valve drive oil pressure 1 nent part of tool G1) to the nipple [1].
a Testing instrument for EGR valve and bypass 4. Start the engine and measure the oil pressure
valve drive oil pressure at low idle and high idle.
Symbol Part No. Part name
G 1
790-261-1204 Digital hydraulic tester
k Stop the machine on level ground, lower

the work equipment to the ground, stop the
engine, and set the parking brake lever and
work equipment lock lever in the lock posi-
tion.
1. Remove oil pressure pickup plug (2) from the

left side of timing gear cover (1).
2. Install nipple [1] of hydraulic tester G1 to the 5. After finishing measurement , remove the mea-
hole from which the oil pressure pickup plug suring instruments and return the removed
was removed. parts.
q Remove the gasket sealant remaining on
the threads of the removed plug with a wire
brush and apply new adhesive or gasket
sealant to the plug before installing.
2 Plug: LT2 or LG-5
3 Plug:
9.8 – 19.6 Nm {1.0 – 2.0 kgm}
16 HM400-2
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low pressure cir-
The common rail fuel injection system (CRI) cuit and high pressure circuit of the fuel system
consists of more precise parts than the con- while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause Feed pump – Fuel filter – Fuel supply
trouble. When testing and maintaining the fuel pump
system, take care more than the past. If dust, High pressure circuit:
etc, sticks to any part, wash that part thor- Fuel supply pump – Common rail –
oughly with clean fuel. Fuel injector
a Precaution for replacing fuel filter cartridge. a The pressure in both low-pressure circuit and
Be sure to use Komatsu genuine fuel filter car- high-pressure circuit lowers to a safety level
tridge. Since the common rail fuel injection automatically 30 seconds after the engine is
system (CRI) consists of more precise parts stopped.
than the conventional fuel injection pump and a Before the fuel circuit is tested and its parts are
nozzle, it employs a high-efficiency special fil- removed, the residual pressure in the fuel cir-
ter to prevent foreign matter from entering it. If cuit must be released completely. Accordingly
a filter other than the genuine one is used, the observe the following.
fuel system may have trouble. Accordingly, k When testing the fuel line or removing or
never use such a filter. installing equipment of fuel system, wait for
at least 30 seconds after the engine is
stopped to release the remaining pressure
in the fuel circuit before starting operation.
(There is still pressure remaining in the cir-
cuit, so do not start operations immediately
after the engine is stopped.)
HM400-2 17
Testing fuel pressure 1 4. Run the engine at high idle and test fuel pres-
sure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part number Part name range, it is normal.
1 Engine speed Fuel pressure
0.15 – 0.3 Mpa
H 2 799-401-2320 Hydraulic tester High idle
{1.5 – 3 kg/cm²}
795-471-1450 Adapter
3
07005-00812 Gasket

2. Remove fuel pressure inspection plug (1)

located at the fuel filter head.
5. When the test is completed, remove the instru-

ments and set to the original condition.
3 Plug: 7.84 – 9.8 Nm {0.8 – 1.0 kgm}
3. Install adapter H3 and install elbow [1] and nip-

ple [2] of hydraulic tester H1. Connect to
hydraulic tester H2.
18 HM400-2
Testing fuel return and leakage amount 1
a Testing instrument of fuel return and leakage

amount.
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 Commercially available Hose
J
4 Commercially available Hose
5 Commercially available Measuring cylinder
6 Commercially available Stop watch
a Since the fuel flows out during the test, prepare

approx. 20 l oil pan (receiver).
HM400-2 19
1. Preparatory work 2) Turn the starting switch ON and set the

1) Open the engine hood. display of machine monitor to the real-time
2) Disconnect tube (3) between supply pump monitoring function (REAL-TIME MONI-
(1) and common rail (2). TOR) display of the service mode.
a Disconnect both end of the tube, q Monitoring system:
loosen clamp and put it aside oppo- MONITOR PANEL
site of cylinder block. q Monitoring code:
3) Insert spacer J1 to supply pump (1) side 01001 (ENG SPEED)
and tighten the removed joint bolt again. a For the operation method, see "Spe-
a Reconnect the return pipe to the fuel cial functions of machine monitor".
tank side.
a Be sure to install gasket to the both
ends of spacer.
3) Run the engine at high idle and stall the

torque converter. When the engine speed
is stabilized, check the leak amount per
4) Insert joint J2 to common rail (2) side and minute with measuring cylinder J5.
tighten the removed joint bolt again. a For the procedure for stalling the
a Be sure to install gasket to the both torque converter, see "Testing torque
ends of joint. converter stall speed".
a The leakage also can be judged by
5) Connect the inspection hose J3 to the end
testing for twenty seconds and triples
of joint J2.
its leakage amount.
a Bind connecting portion with wire so
a If the leakage of pressure limiter is in
that the inspection hose should not
the following range, it is normal.
come off.
a Now the preparation for testing the Leakage
pressure limiter leak amount is com- Engine speed
(cc/min)
pleted. When torque
Max. 10
converter is stalling
2. Testing pressure limiter leakage amount

1) Adjust the route of inspection hose J3 to
remove its sag and insert the hose end 4) When the testing is completed, stop the
into the oil pan (receiver). engine.
20 HM400-2
3. Testing injector return amount return amount per minute with measuring
a During testing injector return amount, cylinder J5.
keep a hose end connected to pressure a Refer to "Testing torque converter
limiter and insert the other end to oil pan stall" for torque converter stall proce-
(receiver). dure.
1) Disconnect return hose (5) of return block a The leakage also can be judged by
(4) portion and connect inspection hose testing for twenty seconds and triples
J4. its leakage amount.
a Block the return hose side with plug a If there is loss of pressure feed from
and fix to fuel tank side. supply pump, the engine speed may
Plug: 07376-70315 not rise. In this case, record the
a Bind connecting portion with wire so engine speed during the test.
that the inspection hose should not a If the return amount of injector (spill
come off. amount) is in the following range, it is
2) Adjust the route of inspection hose J4 to normal.
remove its sag and insert the hose end Torque converter Return limit amount
into the oil pan (receiver). stall speed (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200

machine monitor to the real-time monitor-
ing function (REAL-TIME MONITOR) dis-
play of the service mode.
q Monitoring system:
MONITOR PANEL
q Monitoring code:
01001 (ENG SPEED)
a For the operation method, see "Spe-
5) When the testing is completed, stop the
cial functions of machine monitor".
engine.
4. Operations after completion of testing

If all the tests are completed, remove the
4) Start the engine and run at high idle, and

stall the torque converter. When the
engine speed is stabilized, check the
HM400-2 21
Bleeding air from fuel circuit 1
a Bleed the air as follows if the engine has run

out of fuel or the fuel circuit equipment has
been removed and installed.
2. Remove fuel pre filter (1) and fill up fuel inside.

a When filling, use clean fuel and be careful
not to let dirt get in.
a Confirm the cap is installed to portion (a)
(center hole) of the fuel pre filter and add
fuel from portion (b) (peripheral holes).
a After filling up fuel in fuel pre filter, remove
the cap at portion (a).
a If clean fuel is not available, do not re- 3. Install fuel pre filter (1) to filter head.
move the filter. Operate the priming pump a Apply a thin coat of engine oil on the pack-
(4) to fill the filter with fuel. ing surface of the fuel pre filter.
a Fuel should not be added to fuel main filter a Tighten 3/4 turn after fuel pre filter packing
(2) from outside. surface touches filter head seal surface.
22 HM400-2
7. Crank the engine with the starting motor and

start the engine.
a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there still may
be air in the low-pressure circuit. In this
case, repeat the above procedure from
step 4.
4. Remove air bleeding plug (3) of fuel main filter

(2) and operate priming pump (4).
a Operate until fuel flows through plug hole
and when fuel is confirmed, install the
plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5. Remove air bleeding plug (5) of fuel main filter

and operate priming pump (4).
a Operate until fuel flows through plug hole
and when fuel is confirmed, install the
plug.
a Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
6. Loosen supply pump air bleeder (6) and oper-

ate priming pump (4) 90 – 100 times.
a Operate priming pump until fuel flows
through bleeder and when fuel is con-
firmed, tighten bleeder and operate sev-
er al tim es mor e u nti l p ri m in g pum p
becomes stiff.
a Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}
HM400-2 23
Testing the fuel circuit for 9. Check the fuel piping and the devices for fuel
leakage.
leakage 1 a Check the high-pressure circuit parts con-
k Very high pressure is generated in the high- centrating on the areas coated with the
pressure circuit of the fuel system. If fuel color checker, for fuel leakage.
leaks while the engine is running, it is dan- a If any fuel leakage is detected, repair it
gerous since it can catch fire. and test again from step 1.
a After testing the fuel system or removing and a If any fuel leakage is not detected, inspec-
installing its components, check for fuel leak- tion is completed.
age according to the following procedure.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
1. Spray color checker (developer) over the sup-

ply pump, common rail, injector, and joints of
the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Check the fuel piping and the devices for fuel

leakage.
a Check the high-pressure circuit parts con-
centrating on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and test again from step 1.
4. Run the engine at low idle.

leakage.
centrating on the areas coated with the
6. Run the engine at high idle.

leakage.
centration on the areas coated with the
8. Run the engine at high idle to apply load to the

engine.
a Operate dump LOWER relief.
24 HM400-2
Testing and adjusting fan

belt tension 1
Testing
2. Press the intermediate point between fan pul-

ley and tension pulley with a finger and check
deflection (a).
a Check each belt individually.
a Pressing force:
Approx. 98 N {Approx. 10 kg}
a Deflection (a): 13 – 15 mm (New part)
17 – 19 mm
(when adjusting tension)
Adjusting
a If the deflection is out of range, adjust it ac-
cording to the following procedure.
1. Loosen nut of the back of tension pulley (1).
2. Move tension pulley (3) with adjustment bolt

(2) and adjust belt tension.
a When the belt was replaced with new one,
deflation (a) is 13 – 15 mm.
3. Tighten nut (1).

a After adjusting, check the belt tension
again.
a Check each pulley for broken parts, wear
of groove, wear of belt and check carefully
that the belt does not contact with groove
bottom.
a If the belt extends and looses allowance
for adjustment, or has cuts or cracks,
replace with new one.
HM400-2 25
Testing and adjusting alternator 4. While holding adjustment nut (6), tighten lock-
nut (5).
belt tension 1
k Stop the machine on the level ground, turn 5. Loosen mounting bolts (4) (3) of alternator (2).
the parking brake switch ON, and set a After adjusting, check the belt tension
chocks to the tires. again.
Testing 6. Install belt cover (1) with 2 mounting bolts.

1. Open the engine hood. a Check each pulley for broken parts, wear
of V groove, and check carefully that the V
2. Press the intermediate point between alterna- belt does not contact with V groove bot-
tor pulley and drive pulley with a finger and tom.
check deflection (a). a If the V belt extends and looses allowance
a Check each belt individually. for adjustment, or has cuts or cracks,
a Pressing force: replace with new one.
Approx. 98 N {Approx. 10 kg} a If V belt is replaced, test and adjust again
a Deflection (a): 13 – 16 mm 1 hour after operation.
Adjusting
1. Remove 2 mounting bolts and remove belt

cover (1).
a Remove belt cover only when changing
belt.
2. Loosen mounting bolts (3) (4) of alternator (2).
3. Loosen adjusting rod locknut (5) and move

alternator (2) by turning adjustment nut (6) to
adjust the belt tension.
26 HM400-2
Testing and adjusting air

conditioner compressor belt
tension 1
Testing
2. Press the intermediate point between com-

pressor pulley and drive pulley with a finger
and check deflection (a).
a Pressing force:
Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): Approx. 10 mm
Adjusting
1. Loosen mounting bolt (1).
2. Loosen locknut (2) and move compressor (4)

with bracket by turning adjustment nut (3) to
adjust the belt tension.
3. While holding adjustment nut (3), tighten lock-

nut (2).
4. Tighten mounting bolt (1).

a Test each pulley for broken parts, wear of
V groove, and check carefully that the V
belt does not contact with V groove bot-
tom.
a If the V belt extends and looses allowance
for adjustment, or has cuts or cracks,
replace with new one.
a If V belt is replaced, there is initial expan-
sion, so test and adjust again 2 – 3 days
after operation
HM400-2 27

© 2009 KOMATSU
All Rights Reserved
28 HM400-2
SEN00917-03

HM400-2

HM400-2 2001 and up

Testing torque converter stall speed ............................................................................................................... 3
Testing power train oil pressure ...................................................................................................................... 4
Testing and adjusting of differential lock oil pressure (differential lock spec.)............................................... 12
Adjusting transmission speed sensor ........................................................................................................... 17
Testing and adjusting brake oil pressure....................................................................................................... 19
Testing of accumulator nitrogen gas pressure and procedure
for charging accumulator with nitrogen gas .............................................................................................. 23
Testing brake performance ........................................................................................................................... 27
Bleeding air from brake circuit ...................................................................................................................... 28
Testing wear of wheel brake disc .................................................................................................................. 29
Testing the parking brake pad wear .............................................................................................................. 30
Emergency release of the parking brake ...................................................................................................... 31
Testing and adjusting steering circuit oil pressure ........................................................................................ 32
Testing and adjusting suspension cylinder.................................................................................................... 34
Method of tilting cab up................................................................................................................................. 38
Testing and adjusting dump circuit oil pressure ............................................................................................ 40
HM400-2 1
Adjusting body positioner sensor .................................................................................................................. 42

Adjusting length of spring in body heating spherical joint ............................................................................. 44
Handling of voltage circuit of engine controller ............................................................................................. 44
Adjusting transmission controller .................................................................................................................. 44
Method for emergency escape at electrical system failure ........................................................................... 45
2 HM400-2
Testing torque converter stall 5. When the torque converter oil temperature
goes above 90 °C, run the engine immediately
speed 1 at low idle and return the gear shift lever to the
k Stop the machine on the level ground, turn N position.
k
Never operate the gear shift lever with
the accelerator pedal depressed. Oth-
erwise it may create a large shock and
1. Turn the starting switch ON and set the monitor
may also become the cause of shorten-
panel in the real-time monitoring function
ing the machine's service life.
(REAL-TIME MONITOR) of the service mode.
q Monitoring functions: 2 ITEMS
6. Run the engine at a medium speed, and when
q Monitoring code 1: 01002 (ENG SPEED)
the torque converter oil temperature goes
q Monitoring code 2: 30100 (T/C OIL TEMP)
down to approx. 80 °C, run at low idle.
a For the operation method, see "Special
a Keep the gear shift lever at the N position.
functions of machine monitor".
7. Repeat Steps 3 – 6 and equalize the oil tem-
perature in the torque converter and transmis-
sion.
8. At the same time as repeating Steps 3 and 4,

inspect the stall speed when the torque con-
verter oil temperature is 80 °C.
a Inspect the stall speed 2 or 3 times.
a The stall speed may vary according to the
following conditions, so always inspect the
stall speed at the time of delivery.
1) Variations according to the engine se-
rial number
2) Variations due to atmospheric pres-
2. Start the engine and raise the temperature of
sure and temperature
the torque converter oil and hydraulic oil.
3) Variations due to the torque con-
q Torque converter oil temperature:
sumed by accessories
60 – 80 °C
4) Variations due to characteristics of
q Hydraulic oil temperature: 45 – 55 °C
the torque converter
5) Variations due to the method of in-
3. Turn the parking brake switch ON, depress the
spection
brake pedal, then set the gear shift lever to the
D position.
k If the gearshift lever is operated to any
machine may move off even if the
brake is being depressed, so always
inspect at the D position.
4 Depress the accelerator pedal gradually, run

the engine at high idle and stall the torque con-
verter to raise the torque converter oil temper-
ature.
HM400-2 3
Testing power train oil pressure 1
a List of oil pressure testing points and gauges to

be used
Oil pressure
No. Oil pressure to be inspected gauge
(MPa {kg/cm²})
1 Power train main relief pressure 5.9{60}
2 Torque converter inlet pressure 5.9{60}
3 Torque converter outlet pressure 0.98{10}
Torque converter lock-up clutch
4 5.9{60}
pressure
5 Transmission Lo clutch pressure 5.9{60}
6 Transmission Hi clutch pressure 5.9{60}
7 Transmission 1st clutch pressure 5.9{60}
8 Transmission 2nd clutch pressure 5.9{60}
9 Transmission 3rd clutch pressure 5.9{60}
10 Transmission R clutch pressure 5.9{60}
Inter-axle differential lock clutch
11 5.9{60}
pressure
a The transmission lubrication pressure is repre-

sented by the torque converter outlet port pres-
sure, so there is no need to test it.
4 HM400-2
a Testing instruments for power train oil pressure Overall power train
1. Testing power train main relief pressure
1) Tilt the cab up.
799-101-5002 Hydraulic tester 2) Remove oil pressure inspecting plug (1),
1
K 790-261-1204 Digital type hydraulic tester then install nipple [1] and hose [2] of
2 799-401-2320 Hydraulic tester hydraulic tester K1.
a Pull the hose out to the rear of the
k Stop the machine on the level ground, turn transmission.
k Install and remove the testing instrument
after the oil temperature is cooled enough.
k When testing the oil pressure while travel-
ing, make sure that there is a wide travel
area and pay attention to keep the safety in
the surrounding area.
a When tilting the cab up or down, see "Method
of tilting cab up" for details.
3) Tilt the cab down and return it to its origi-

nal position.
4) Connect oil pressure gauge [3] of hydrau-
lic tester K1.
a If oil pressure gauges are of the ana-
log type, use the one with rated pres-
sure 6 MPa {60 kg/cm²}.
of the torque converter oil to the operating
range.
6) While keeping the gear shift lever at the N
position, inspect the oil pressure at low
idle and high idle.
7) When the test is completed, remove the

instruments and restore to the original
condition.
HM400-2 5
Torque converter related 3. Testing torque converter outlet pressure

2. Testing torque converter inlet pressure 1) Tilt the cab up.
1) Install hose [1] of hydraulic tester K1 to oil 2) Remove oil pressure inspecting plug (3),
pressure inspecting coupler (2). then install nipple [1] and hose [2] of
hydraulic tester K1.
a Pull the hose out to the rear of the
transmission.
2) Connect hydraulic tester K2.

range. 3) Tilt the cab down and return it to its origi-
4) While keeping the gear shift lever at the N nal position.
position, inspect the oil pressure at high 4) Connect oil pressure gauge [3] of hydrau-
idle. lic tester K1.
range.
position, inspect the oil pressure at high
idle. When operate retarder control lever
at actuation position and release position.

condition.

condition.
6 HM400-2
4. Testing torque converter lock-up clutch Transmission related

pressure a Table of gear shift lever positions, speed
1) Remove ECMV cover. ranges, and clutches actuated
2) Remove oil pressure inspecting plug (4),
then install nipple [1] and hose [2] of Gear shift lever Clutch
Travel
speed
hydraulic tester K1. R2 R1 N D 5 4 3 2 1 Lo Hi 1st 2nd 3rd R
Q Q Q Q Q F1 q q
Q Q Q Q Q F2 q w
Q Q Q Q F3 w q
Q Q Q F4 w w
Q Q F5 w q
Q F6 w w
Q N
Q R1 w q
Q R2 w w
a The Q mark indicates the travel speed ranges

3) Connect oil pressure gauge [3] of hydrau- that are actuated for each position of the gear
lic tester K1. shift lever.
a If oil pressure gauges are of the ana- a The w mark and q mark indicate the clutches
log type, use the one with rated pres- that are actuated for each travel speed.
sure 6 MPa {60 kg/cm²}. a The q mark indicates the travel gear speed
4) Start the engine and raise the temperature when testing the oil pressure for each clutch.
range.
5) Turn the parking brake OFF, depress the
brake pedal, then set the gear shift lever
to position 1.
6) Release the brake, travel at high idle, and
inspect the oil pressure when the lock-up
pilot lamp lights up.
k In F1 gear speed, the maximum
travel speed reaches approx. 7km/
h, so drive the machine consider-
ing the safety of the surrounding
area.

condition.
HM400-2 7
5. Testing transmission Lo clutch pressure 6. Testing transmission Hi clutch pressure

1) Remove ECMV cover. 1) Remove ECMV cover.
2) Remove oil pressure inspecting plug (5), 2) Remove oil pressure inspecting plug (6),
then install nipple [1] and hose [2] of then install nipple [1] and hose [2] of
hydraulic tester K1. hydraulic tester K1.
3) Connect oil pressure gauge [3] of hydrau- 3) Connect oil pressure gauge [3] of hydrau-
lic tester K1. lic tester K1.
a If oil pressure gauges are of the ana- a If oil pressure gauges are of the ana-
log type, use the one with rated pres- log type, use the one with rated pres-
sure 6 MPa {60 kg/cm²}. sure 6 MPa {60 kg/cm²}.
4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF, depress 5) Turn the parking brake switch OFF, depress
the brake pedal, then set the gear shift lever the brake pedal, then set the gear shift lever
to position 1. to position 2.
6) Release the brake and inspect the oil 6) Release the brake, travel at high idle, and
pressure when traveling at high idle. inspect the oil pressure when the shift
k
indicator displays [F2].
In F1 gear speed, the maximum
travel speed reaches approx. 7km/ k In F2 gear speed, the maximum
h, so drive the machine consider- travel speed reaches approx.
ing the safety of the surrounding 11km/h, so drive the machine con-
area. sidering the safety of the sur-
rounding area.

instruments and restore to the original 7) When the test is completed, remove the
condition. instruments and restore to the original
condition.
8 HM400-2
7. Testing transmission 1st clutch pressure 8. Testing transmission 2nd clutch pressure
range. range.
to position 1. to position 3.
6) Release the brake and inspect the oil 6) Release the brake, travel at high idle, and
pressure when traveling at high idle. inspect the oil pressure when the shift
k
In F1 gear speed, the maximum
travel speed reaches approx. 7 km/ k In F3 gear speed, the maximum
h, so drive the machine consider- travel speed reaches approx. 17
ing the safety of the surrounding km/h, so drive the machine consid-
area. ering the safety of the surrounding
area.

instruments and restore to the original 7) When the test is completed, remove the
condition. instruments and restore to the original
condition.
HM400-2 9
9. Testing transmission 3rd clutch pressure 10. Testing transmission R clutch pressure
range. range.
to position 5. to position R1.
6) Release the brake, travel at high idle, and 6) Release the brake and inspect the oil
inspect the oil pressure when the shift pressure when traveling at high idle.
k
In R1 gear speed, the maximum
k In F5 gear speed, the maximum travel speed reaches approx. 7 km/
travel speed reaches approx. 40 h, so drive the machine consider-
km/h, so drive the machine consid- ing the safety of the surrounding
ering the safety of the surrounding area.
area.

7) When the test is completed, remove the instruments and restore to the original
instruments and restore to the original condition.
condition.
10 HM400-2
11. Testing inter-axle differential lock clutch

pressure
1) Remove ECMV cover.
2) Remove oil pressure inspecting plug (11),
then install nipple [1] and hose [2] of
hydraulic tester K1.

lic tester K1.
range.
position, move the inter-axle differential
lock switch to the "MANUAL" position.
6) Inspect the oil pressure while the engine is
running at high idle.

condition.
HM400-2 11
Testing and adjusting of 4) Connect oil pressure gauge [2] of hydrau-

differential lock oil pressure lic tester L1.
(differential lock spec.) 1 log type, use the one with rated pres-
a Equipment for testing and adjusting the differ- sure 6 MPa {60 kg/cm²}.
ential lock oil pressure 5) Start the engine and inspect the oil pres-
sure at high idle with manual operation
Symbol Part number Part name button (2) of solenoid valve to operate dif-
799-101-5002 Hydraulic tester ferential lock pushed.
L a This operation should be carried out
by 2 people. One keeps manual oper-
k Stop the machine on the level ground, turn ation button of solenoid valve pushed
the parking brake switch ON, and set and another operates accelerator
chocks to the tires. pedal on operator's seat and checks
k Install and remove the testing instrument the oil pressure.
after the oil temperature is cooled enough. a When the machine is stopped, differ-
ential oil pressure is applied only
Testing when manual operation button of
solenoid valve is pushed.
1. Testing the oil pressure of the front axle dif-
ferential lock
1) Tilt the cab up.
a See "Method of tilting cab up" for de-
tails.
2) Remove front differential lock oil pressure
inspection plug (1).
3) Install nipple and hose [1] of hydraulic

tester L.

condition.
12 HM400-2
2. Testing the differential lock oil pressure for

center axle
1) Raise the body to stroke end
k Fix the body with the safety pin.
2) Remove center differential lock oil pres-
sure inspection plug (3).

tester L.

condition.

lic tester L1.
5) Start the engine and inspect the oil pres-
button (2) of solenoid valve to operate dif-
ferential lock pushed.
a This operation should be carried out
ation button (2) of solenoid valve
pushed and another operates accel-
erator pedal on operator's seat and
checks the oil pressure.
a When the machine is stopped, differ-
when manual operation button of
HM400-2 13
3. Testing the differential lock oil pressure for

rear axle
1) Raise the body to stroke end
k Fix the body with the body pivot
pin.
2) Remove rear differential lock oil pressure
inspection plug (4).

tester L.

condition.

lic tester L1.
5) Start the engine and inspect the oil pres-
button (2) of solenoid valve to operate dif-
ferential lock pushed.
a This operation should be carried out
ation button (2) of solenoid valve
pushed and another operates accel-
erator pedal on operator's seat and
checks the oil pressure.
a When the machine is stopped, differ-
when manual operation button of
14 HM400-2
Adjusting 2. Adjusting the differential lock oil pressure

1. Adjusting the differential lock oil pressure for center axle
for front axle a If the center axle differential lock oil pres-
a If the front axle differential lock oil pressure is not normal, adjust it with relief
sure is not normal, adjust it with relief valve (9) of center differential lock valve
valve (5) of front differential lock valve according to the following procedures.
according to the following procedures.
1) Remove cap (10).

1) Remove cap (6). 2) While holding adjustment screw (12),
2) While holding adjustment screw (8), loosen locknut (11).
loosen locknut (7). 3) Turn adjustment screw (12) to adjust the
3) Turn adjustment screw (8) to adjust the oil oil pressure.
pressure. a Adjustment screw:
a Adjustment screw: q When turned clockwise, the oil
q When turned clockwise, the oil pressure is heightened.
pressure is heightened. q When turned counterclockwise,
q When turned counterclockwise, the oil pressure is lowered.
the oil pressure is lowered. 4) While holding adjustment screw (12),
4) While holding adjustment screw (8), tighten locknut (11).
tighten locknut (7). 5) Install cap (10).
5) Install cap (6). a After completing the adjustment,
a After completing the adjustment, check the oil pressure again following
check the oil pressure again following the procedure for the above test.
the procedure for the above test.
HM400-2 15
3. Adjusting the differential lock oil pressure

for rear axle
a If the rear axle differential lock oil pressure
is not normal, adjust it with relief valve (13)
of rear differential lock valve according to
the following procedures.
a Procedure for adjustment is the same as

for center differential lock valve.
16 HM400-2
Adjusting transmission speed sensor 1
a There are 4 speed sensors installed to the 4) Tighten nut (3) with sensor (1) fixed.
transmission. Adjust each sensor according to 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
N1 : Input shaft speed sensor
N2 : Intermediate shaft speed sensor
N3 : Output shaft R speed sensor
FE1 : Output shaft F speed sensor
a For the input shaft speed sensor, tilt up the cab
before carrying out adjustment.
a For the intermediate shaft speed sensor, out-
put shaft F speed sensor and output shaft R
speed sensor, remove the transmission and
front differential assembly from machine before
carrying out adjustment.
1. Adjusting the input shaft speed sensor (N1)

1) Remove input shaft speed sensor (1) and 2. Adjusting the intermediate shaft speed sen-
check that the tip is free of steel chips and sor (N2)
flaws, and then reinstall it temporarily to 1) Remove intermediate shaft speed sensor
the original position. (4) and check that its tip is free from steel
2 Threaded section: chips and flaws, and then reinstall it tem-
Gasket sealant (LG-5) porarily to the original position.
2) Screw in sensor (1) until its tip touches the 2 Threaded section:
addendum of input shaft gear (2). Gasket sealant (LG-5)
3) Return sensor (1) by 1/2 – 1 turn from that 2) Screw in sensor (4) until its tip touches the
position. addendum of intermediate shaft gear (5).
a Clearance (a) which is created be- 3) Return sensor (4) by 1/2 – 1 turn from that
tween the sensor tip and addendum position.
is 0.75 – 1.5 mm.
HM400-2 17
a Clearance (b) which is created be- 2) Screw in sensor (10) until its tip touches
tween the sensor tip and addendum the addendum of front output shaft gear
is 0.75 – 1.5 mm. (11).
4) Tighten nut (6) with sensor (4) fixed. 3) Return sensor (10) by 1/2 – 1 turn from
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm} that position.
a Clearance (d) which is created be-
tween the sensor tip and addendum
is 0.75 – 1.5 mm.
4) Tighten nut (12) with sensor (10) fixed.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
3. Adjusting the output shaft R speed sensor

(N3)
1) Remove output shaft R speed sensor (7)
and check that its tip is free from steel
chips and flaws, and then reinstall it tem-
porarily to the original position. 5. Confirming sensor input signal
2 Threaded section: After completing adjustment, confirm that each
Gasket sealant (LG-5) transmission shaft speed is displayed normally
2) Screw in sensor (7) until its tip touches the with the real time monitoring function (REAL-
addendum of rear output shaft gear (8). TIME MONITOR) of the service mode of the
3) Return sensor (7) by 3/4 – 1 turn from that machine monitor.
position. a For the details of the real time monitoring
a Clearance (c) which is created be- f u n c t i o n , s e e " Sp e c i a l f u n c t i o n s o f
tween the sensor tip and addendum machine monitor".
is 1.1 – 1.5 mm.
4) Tighten nut (9) with sensor (7) fixed.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
4. Adjust output shaft F speed sensor (FE1)

1) Remove output shaft F speed sensor (10)
and check that its tip is free from steel
chips and flaws, and then reinstall it tem-
porarily to the original position.
2 Threaded section:
Gasket sealant (LG-5)
18 HM400-2
Testing and adjusting brake oil (Testing with diagnosing devices)

pressure 1 1. Testing the charge valve cut-in pressure
and cut-out pressure
a Equipment for testing and adjusting brake oil a Inspect the charge valve oil pressure at
pressure remote pressure pickup port (1).
1
M 790-261-1204 Digital hydraulic tester
2 793-520-1805 Brake test kit

Testing
1. Testing ACC (accumulator) charge oil pres-
sure
(Method using monitoring) 1) Install hose [1] of hydraulic tester M1 and
1) Set the machine monitor in service mode connect oil pressure gauge [2].
and display the following 2 items simulta- a If oil pressure gauges are of the ana-
neously with the monitoring function. log type, use the one with rated pres-
q Monitoring system: 2 ITEMS sure 40 MPa {400 kg/cm²}.
q Monitoring code: 35500 (ACC OIL PRESS F)
q Monitoring code: 35501 (ACC OIL PRESS R)
a For the operating method, see "Special func-
tions of machine monitor (EMMS)".
2) Start the engine.

3) Test the cut-in pressure at high idle.
1] Press and release the brake pedal
repeatedly to lower the oil pressure in
the accumulator.
2] Read the lower one of the ACC oil
pressures (front or rear) when it starts
rising after it reaches the bottom.
4) Test the cut-out pressure at high idle.
q Read the ACC oil pressure (front or
rear) when it stops rising at the high-
est point after the cut-in pressure.
HM400-2 19

3) Inspect the cut-in pressure at high idle.
1] Pump the brake pedal repeatedly to
gradually lower the pressure inside
the accumulator.
2] Inspect the pressure at the point
where the indicator of oil pressure
gauge [2] stops going down and
starts to go up again.
4) Inspect the cut-out pressure at high idle.
Check the oil pressure when the pressure
goes up after the cut-in and the indicator
of oil pressure gauge [2] stops.
3) Inspect the actuating pressure of the foot
brake under the following conditions.
1] Run the engine for several minutes at
low idle to charge the accumulator,
then stop the engine.
2] Depress the brake pedal fully and
inspect the oil pressure.
4) Inspect the actuating pressure of the
retarder brake under the following condi-
tions.
1] Run the engine for several minutes at
low idle to charge the accumulator,
5) When the test is completed, remove the 2] Turn the starting switch ON.
instruments and restore to the original 3] Pull the retarder lever fully and in-
condition. spect the oil pressure.
5) Inspect the drop in pressure of the foot
2. Testing the wheel brake actuating pressure brake under the following conditions.
and drop in pressure a Check that the actuating pressure of
a Inspect the front brake circuit, center both the foot brake and the retarder
brake circuit and rear brake circuit using are normal before starting to mea-
the same procedure. sure.
1) Remove air bleeder (2) of the slack 1] Run the engine for several minutes at
adjuster. low idle to charge the accumulator,
2] Depress the brake pedal fully and
inspect the oil pressure.
a Keep the brake pedal depressed.
3] Inspect the oil pressure after 5 min-
utes and calculate the drop in pres-
sure.
condition.
a Bleed the air from the brake circuit
referring to "Bleeding air from brake
circuit" section.
2) Install brake test kit M2 and bleed the air
from the brake circuit.
a For details, see "Bleeding air from
brake circuit" section.
20 HM400-2
3. Inspect the actuating pressure of the park- 7) When the test is completed, remove the
ing brake instruments and restore to the original
1) Turn the parking brake switch ON. condition.
k
2) Remove oil pressure inspection plug (3) in
Check that the parking brake
parking brake cylinder piping.
switch is ON before carrying out
the operation.
3) Install nipple [1] and hose [2] of hydraulic

tester M1 and connect oil pressure gauge
[3].
4) Start the engine and operate the parking

brake switch several times at high idle to
bleed air from the circuit.
5) Stop the engine and turn the starting
switch ON.
6) Inspect the oil pressure when parking
brake switch is turned OFF.
HM400-2 21
Adjusting
Adjusting charge valve cut-in pressure and cut-
out pressure
a If the charge valve cut-in pressure or cut-out
pressure is not normal, adjust the R1 relief
valve of charge valve (4) according to the fol-
lowing procedures.
a Both cut-in pressure and cut-out pressure
change by adjusting the R1 relief valve.
1. Remove the mudguard sheet in the left front

tire housing.
2. While holding adjustment screw (5), loosen

locknut (6).
3. Turn adjustment screw (5) to adjust the oil

pressure.
a Adjustment screw:
q When turned clockwise, the oil pres-
sure is heightened.
q When turned counterclockwise, the
oil pressure is lowered.
4. While holding adjustment screw (5), tighten

locknut (6).
3 Locknut: 10.2 Nm {1 kgm}
a After completing the adjustment, check
the oil pressure again following the proce-
dure for the above test.
22 HM400-2
Testing of accumulator nitrogen

gas pressure and procedure for
charging accumulator with
nitrogen gas 1
a Testing instrument
Symbol Part No. Part name Remarks
R1 792-610-1700 Gas charge tool —
Nipple
792-610-1310 (For Russia) GOST
Nipple
792-610-1320 CGA No. 351
(For USA)
Nipple
R2 792-610-1330 (For USA) ASA B-571-1965
3. Connect gas charge tool R1 to valve (4) of
DIN 477-1963 accumulator (1) according to the following pro-
792-610-1350 Nipple NEN 3268-1966 cedure.
(For Germany) SIS-SMS 2235/2238
1) Turn handle (a) of gas charge tool R1 to
792-610-1360 Nipple (For UK) BS 341 Part 1-1962
the left until it stops.
Nitrogen gas cylinder (c) must be
k
q
Put on proper protection gear (goggles, connected even when you measure
leather gloves and protective clothes) so only the gas pressure.
that the leaking nitrogen gas will not touch q Close the valve of nitrogen gas cylin-
your skin or clothes and work on the wind- der (c) and handle (b).
ward side as long as possible. For connection of nitrogen gas cylin-
k
q
When handling nitrogen gas in a room or der (c) and gas charge tool R1, see
another place which is not ventilated well, "Procedure for charging accumulator
ventilate the work place forcibly and observe with nitrogen gas".
the Oxygen Deficiency Prevention Rules of
2) Connect gas charge tool R1 to valve (4) of
the Labor Safety and Sanitation Law.
k
accumulator (1).
Since the accumulator is charged with
high-pressure nitrogen gas, wrong han-
dling of it can cause an explosion and
injury or death. When handling the accu-
mulator, observe the following strictly.
q Do not bring fire near the accumulator or
put the accumulator in fire.
q Do not drill, weld or gas-cut the accumulator.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
Testing of accumulator nitrogen gas pressure

a The nitrogen gas pressure in the accumulator
disconnected from the machine can be mea-
sured according to the following procedure, too.
1. Stop the engine and press the brake pedal
repeatedly to lower the oil pressure in the
brake circuit to zero.
a Generally, if the brake pedal is pressed 30
times, the reaction force to the brake
pedal is lost and the oil pressure is low-
ered to zero.
2. Remove valve guard (2) and cap (3) from
accumulator (1).
HM400-2 23
4. Turn handle (a) of gas charge tool R1 to the 6. Remove gas charge tool R1 from accumulator
right slowly and read the gauge. (1) and return the removed parts. See "Proce-
a Since the indicated value varies with the dure for charging accumulator with nitrogen
ambient temperature, charge the gas gas".
pressure referring to the following chart.
(The unit of each value in the formula is Procedure for charging accumulator with nitro-
°C.) gen gas
Indicated gas pressure = a The disconnected from the machine can be
Standard gas pressure x ((273 + t)/ charged with nitrogen gas according to the fol-
(273 + 20)) lowing procedure, too.
Carging accumulator with nitrogen gas chart 1. Stop the engine and press the brake pedal
Ambient Carging nitrogen gas repeatedly to lower the oil pressure in the
temperture Remarks brake circuit to zero.
C° MPa kg/cm2 a Generally, if the brake pedal is pressed 30
15 4.34 44.2 times, the reaction force to the brake
16 4.35 44.4 pedal is lost and the oil pressure is low-
17 4.37 44.5 ered to zero.
18 4.38 44.7
19 4.40 44.8 2. Remove valve guard (2) and cap (3) from
20 4.41 45.0
Standard gas accumulator (1).
pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.50 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2 3. Connect gas charge tool R1 and nitrogen gas
35 4.64 47.3 cylinder (c) to valve (4) of accumulator (1)
36 4.65 47.5 according to the following procedure.
37 4.67 47.6 1) Turn handle (a) of gas charge tool R1 to
38 4.68 47.8 the left until it stops.
39 4.70 47.9 2) Turn handle (b) to the left to open.
40 4.71 48.1 3) Connect gas charge tool R1 to valve (4) of
41 4.73 48.2 accumulator (1).
42 4.74 48.4 4) Connect gas charge tool R1 and nitrogen
43 4.76 48.5 gas cylinder (c).
44 4.77 48.7 q There are 2 types of threads of nitro-
45 4.79 48.8 gen gas cylinders, W22-14 thread
(mail screw, type A) and W23-14
t = Gas temperature at time of charge (°C) thread (female screw, type B). When
Reference: t may be assumed to be ambi- using a gas cylinder of W23-14 thread
ent temperature. (female screw, type B), connect the
hose by using the adapter. (The
5. If the gas pressure is too high or too low, adjust adapter is attached to gas charge tool
it referring to "Procedure for charging accumu- R1.) [For Japan]
lator with nitrogen gas". q Use nipple R2 to connect the hose,
a Each time the pressure is measured, some depending on the specification of the
nitrogen gas is discharged and the pres- nitrogen gas cylinder. [For overseas]
sure lowers. Add nitrogen gas by the loss.
24 HM400-2
Carging accumulator with nitrogen gas chart

Ambient Carging nitrogen gas
temperture Remarks
C° MPa kg/cm2
15 4.34 44.2
16 4.35 44.4
17 4.37 44.5
18 4.38 44.7
19 4.40 44.8
Standard gas
20 4.41 45.0 pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.50 45.9
27 4.52 46.1
28 4.53 46.2
29 4.55 46.4
30 4.56 46.5
31 4.58 46.7
32 4.59 46.8
33 4.61 47.0
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
4. Open nitrogen gas cylinder (c) slightly to dis- 37 4.67 47.6
charge nitrogen gas at pressure of 0.19 – 0.29 38 4.68 47.8
MPa {2 – 3 kg/cm²}. 39 4.70 47.9
40 4.71 48.1
5. After nitrogen gas starts flowing out of handle 41 4.73 48.2
(b), close handle (b). 42 4.74 48.4
43 4.76 48.5
6. Turn handle (a) slowly to the right to open 44 4.77 48.7
valve (4) of accumulator (1) gradually. 45 4.79 48.8
a If handle (a) is turned too much, the valve
core of the accumulator will be damaged t = Gas temperature at time of charge (°C)
and gas will leak. Accordingly, operate Reference: t may be assumed to be ambi-
handle (a) carefully. ent temperature.
7. Open the valve of nitrogen gas cylinder (c) fur- 9. After the accumulator is charged to the stan-
ther to charge the accumulator with nitrogen dard pressure, close the valve of nitrogen gas
gas. cylinder (c).
q If the accumulator is charged too much,
turn handle (b) to the left slowly with the
8. During the work, close the valve of nitrogen
valve of nitrogen gas cylinder (c) closed to
gas cylinder (c) and check the nitrogen gas
release the nitrogen gas gradually to
pressure in the accumulator.
adjust.
a Since the indicated value varies with the
ambient temperature, charge the gas
pressure referring to the following chart.
(The unit of each value in the formula is
°C.)
Indicated gas pressure =
Standard gas pressure x ((273 + t)/
(273 + 20))
HM400-2 25
10. Remove gas charge tool R1 from valve (4) of

accumulator (1) according to the following pro-
cedure.
1) Turn handle (a) to the left to close the
valve of the accumulator.
2) Turn handle (b) to the left to open and dis-
charge nitrogen gas remaining in gas
charge tool R1 and hoses.
3) Remove gas charge tool R1 from valve (4)
of the accumulator.
11. Apply soap water to valve (4) of the accumula-

tor to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumula-

tor (1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
13. In a week after charging the accumulator with

nitrogen gas, check that the nitrogen gas pres-
sure has not lowered.
a Check the functions in 5 minutes after
stopping the engine. (If the engine is
stopped for more than 5 minutes, the
brake circuit pressure lowers and the func-
tions cannot be checked accurately.)
1) Stop the machine on a level place and set
the parking brake switch in the "PARK"
position.
2) Start the engine and run it at medium
speed for 1 minute and then stop it.
3) Turn the starting switch to the ON position
and press the brake pedal repeatedly.
Count the number of presses until the
brake oil pressure caution lamp lights up.
q If number of presses is less than 5:
Accumulator gas pressure may have
lowered.
q If number of presses is 5 or more:
Accumulator gas pressure is normal.
26 HM400-2
Testing brake performance 1

k Stop the machine on the level ground and
turn the parking brake switch ON.
1. Test braking performance of foot brake

1) Start the engine and turn the parking
brake switch OFF.
2) Depress the brake pedal fully, then set the
gear shift lever to the D position.
a Do not set the gear shift lever to the
position other than D, when testing
the foot brake performance.
3) Depress the accelerator pedal gradually
and check that the machine does not 4) After completing the test, run the engine at
move when the torque converter is stalled low idle and set the gear shift lever to the
at the specified speed. N position.
3. Testing the braking performance of parking

brake
k If the machine starts to move, it can
cause a serious personal injury. Should
the machine start moving during the
performance test, reduce the engine
speed immediately, move the gear shift
lever to the N position and depress the
foot brake.
1) Turn the parking brake switch ON and
start the engine.
2) Set the gear shift lever to the D position.
4) After completing the test, run the engine at a Do not set the gear shift lever to the
low idle and set the gear shift lever to the position other than D, when testing
N position. the parking brake performance.
2. Test braking performance of retarder brake and check that the machine does not
1) Start the engine and turn the parking move when the torque converter is stalled
brake switch OFF. at the specified speed.
2) Pull the retarder lever fully, then set the a If the machine moves at a revolution
gear shift lever to the D position. lower than specified, adjust the clear-
a Do not set the gear shift lever to the ance of the brake pad referring to "2.
position other than D, when testing Adjusting pad clearance" in "Testing
the retarder brake performance. wear of parking brake pad".
and check that the machine does not
move when the torque converter is stalled
at the specified speed.
4) After completing the test, run the engine at

low idle and set the gear shift lever to the
N position.
HM400-2 27
Bleeding air from brake circuit 1 5) After completing air bleeding, set to the
original condition.
a Bleed the air from brake circuit as follows if the
brake circuit equipment has been removed and 2. Bleeding air from wheel brake section of
installed. foot brake circuit.
a When bleeding the air from the wheel brake a Implement the same procedure for the
circuit, always bleed the air from the slack front brake circuit, center brake circuit and
adjuster section first, then bleed the air from rear brake circuit.
the wheel brake section. a The retarder oil pressure caution lamp
may light up while air is being bled. If it
1. Bleeding air from slack adjuster section of lights up, tighten the air bleeder and check
wheel brake circuit the oil level in the brake oil tank by the
a Implement the same procedure for the sight gauge. If the oil level is low, add oil.
front brake circuit, center brake circuit and 1) Connect air bleed hose [2] to air bleeder
rear brake circuit. (2).
a The retarder oil pressure caution lamp
may light up while air is being bled. If it
lights up, tighten the air bleeder and check
the oil level in the brake oil tank by the
sight gauge. If the oil level is low, add oil.
1) Connect air bleed hose [1] to air bleeder
(1).
2) Run the engine and operate at low idle.

3) Depress the brake pedal fully and hold it in
position.
4) Loosen air bleeder (2) approx. 1/2 turn,
then drain the oil mixed with the air.
5) When no more air comes out with the oil,
tighten air bleeder (2).
2) Run the engine and operate at low idle. 6) After bleeding air, set to the original condi-
3) Bleed the air from the brake pedal circuit tion.
as follows.
1] Depress the brake pedal fully and 3. Bleeding air from parking brake circuit
hold it in position. 1) Run the engine and operate at low idle.
2] Loosen air bleeder (1) approx. 1/2 2) Turn the parking brake switch ON and
turn, then drain the oil mixed with the OFF several times.
air. a The air is automatically bled with this
3] When no more air comes out with the operation.
oil, tighten air bleeder (1).
3 Air bleeder:
10 – 20 Nm {1 – 2 kgm}
4) Bleed the air from the retarder brake cir-
cuit as follows.
1] Pull the retarder lever fully and hold it
in position.
2] Loosen air bleeder (1) approx. 1/2
turn, then drain the oil mixed with the
air.
3] When no more air comes out with the
oil, tighten air bleeder (1).
3 Air bleeder:
10 – 20 Nm {1 – 2 kgm}
28 HM400-2
Testing wear of wheel brake disc 1 a Limit mark (b) indicates the wear limit for
the disc.
k Stop the machine on the level ground, turn If limit mark (b) reaches the end face of
the parking brake switch ON, and set guide (3), the disc has reached the wear
chocks to the tires. limit.
k Carry out the test when the brake oil tem-
perature is less than 60 °C.
k When the disc comes close to the wear
limit, carry out the test more frequently. Be
sure to test a braking performance of
retarder brake at the same time.
1. Check that the brakes other than parking brake

are not being applied.
2. Turn the starting switch ON and check that the

retarder oil pressure caution lamp has not lit
up.
a If the lamp lights up, the oil pressure in the
brake circuit has dropped, so start the 6. Install cap nut (1) of the gauge.
engine and run it at approx. 2,000 rpm. 3 Cap nut: 29.4 – 39.2 Nm {3.0 – 4 kgm}
When the lamp goes out, stop the engine.
3. Remove cap nut (1) of the gauge.
4. Depress the brake pedal fully and hold it in

position.
a When the engine is started, the brake
cooling oil is actuated and the test cannot
be carried out accurately, so always stop
the engine before carrying out the test.
5. Push in rod (2) of the gauge until it contacts the

piston and judge the amount of wear.
a There are three marks (A, B and C) on the
rod. For HM400-2 model, use mark A.
a With a new machine, the initial mark (a) on
rod (2) is aligned with the end face of
guide (3).
The adjustment position may move out of
alignment, so do not loosen the locknut of
guide (3) except when replacing the disc.
HM400-2 29
Testing the parking brake pad

wear 1
k Stop the machine on the level ground, and
set chocks to the tires.
a Before carrying out the test, start the engine
and raise up the dump body to the stroke end.
Then insert the body pivot pin and stop the
engine.
1. Testing wear of pad

1) Turn the starting switch ON and the park-
ing brake switch OFF to release the park-
ing brake.
2) Remove the top cover of the parking 2. Adjusting pad clearance
brake. a When the wear of pads was tested, or
3) Release the parking brake by turning when the pads were replaced with new
adjustment nut (1) counter-clockwise. ones, adjust the clearance in the following
manner.
1) Turn the starting switch ON and the park-
ing brake switch OFF to release the park-
ing brake.
2) Install two pads (5).
3) Install two each of springs (4) and (3) to
left and right brackets (2), and then install
left and right brackets (2).
a There are two types of springs, so
check the color, and be careful not to
mistake the mounting position.
q Spring (4): Yellow
q Spring (3): Black
a Tighten the bracket mounting bolts
4) Remove left and right brackets (2), and
temporarily by 2 to 3 turns.
then remove two each of springs (3) and
4) Turn adjustment nut (1) clockwise until
(4).
brake pad (5) comes into close contact
5) Remove two pads (5).
with disc (6).
5) Checking the clearance between pad (5)
and disc (6), turn adjustment nut (1) coun-
terclockwise until it reaches the defined
clearance.
a Standard clearance (total of b and c):
1.5 mm
6) Test the thickness (a) of pads (5).

a Thickness limit of pad: 1.5mm
a If either the front or rear pad has
reached the thickness limit, replace
both pads at the same time.
30 HM400-2
Emergency release of the parking

brake 1
a If any problem occurs in the electrical system
or hydraulic system of the parking brake and
the parking brake is not released, it is possible
to release the brake temporarily as follows.
k If any problem occurs in the hydraulic sys-
tem, there is a strong possibility that the
wheel brake does not work properly, so
after releasing the parking brake, always
tow the machine at low speed to move.
k When carrying out the operation to release
the parking brake, stop the machine on a
level ground and check that the surround-
7) Apply and release the parking brake
ing area is safe before starting the opera-
switch repeatedly in order to adjust the
tion. If the parking brake must be released
pad clearance.
o n a slo p e i n a n e mer g en c y o r o t h e r
a Since adjustment nut (1) turns clock-
unavoidable situation, set chocks to the
wise while releasing the parking
tires securely.
brake, repeat the operation until it
stops turning.
1. In order to create a gap between the pad and
8) Release the parking brake and check the
disc, turn the parking brake adjustment screw
clearance of the pad again.
(1) counterclockwise.
1.5 mm
a If the clearance is not correct, carry
out the adjustment again from step 3).
9) Tighten the mounting bolts of left and right
brackets (2).
a Be careful not to let the mounting
position move out of alignment.
10) Check the clearance between pad (5) and
disc (6) again.
0.5 mm
a If the clearance on one side is narrow,
move the mounting position of the left
and right brackets to adjust.
2. Tow the machine to a safe place.
a After moving the machine, set chocks
securely to the tires.
HM400-2 31
Testing and adjusting steering cir-

cuit oil pressure 1
a Equipments for testing and adjusting steering
circuit oil pressure
N
790-261-1204 Digital type hydraulic tester

1. Adjusting steering relief oil pressure instruments and restore to the original
a Measure the steering relief pressure at condition.
remote pressure pickup port (1).
2. Adjusting steering relief oil pressure
a If the steering relief oil pressure is not cor-
rect, adjust relief valve (2) of the flow amp
valve as follows.
1) Install hose [1] of hydraulic tester N and

connect oil pressure gauge [2].
sure 40 MPa {400 kg/cm²}. 1) Remove plug (3) and then locknut (4).
2) Turn adjustment screw (5) and adjust oil
pressure.
a Adjustment screw:
q When turned clockwise, the oil
pressure is heightened.
q When turned counterclockwise,
the oil pressure is lowered.
2) Start engine and operate the steering up

to either left or right stroke end.
3) Measure the oil pressure when the steer-
ing circuit pressure is relieved with the
engine at high idle.
32 HM400-2
3) Install locknut (4) and then plug (3).

a After completing the adjustment, check
the oil pressure again following to the
procedure for test above.
HM400-2 33
Testing and adjusting

suspension cylinder 1
a Equipment for testing and adjusting suspen-
sion cylinder
1 792-610-1000 Suspension tool
2 792-610-1130 • Pump
3 792-610-1110 • Hose
4 792-610-2200 • Joint
5 07020-21732 • Fitting
6 792-610-1140 • Joint
P 7 792-610-1250 • Valve
8 792-610-1260 • Nipple
9 792-610-1270 • Hose
10 792-610-1640 • Joint
11 792-610-1400 • Regulator
12 792-610-1430 • Gauge
13 792-610-1440 • Gauge

1. Testing cylinder length

2. Releasing nitrogen gas
Test the installation length of the suspension
1) Set a hydraulic jack under the frame of the
cylinder under the following conditions.
machine and raise it until tires come
q On a level road surface
slightly off the ground.
q Stop engine.
a Use a 50 ton {490,000 N} jack.
q Dump body unloaded
a Installed length (a) of front cylinder: k Set the jack securely under the
153 ± 10 mm frame.
Installed length (b) of rear cylinder: a When carrying out the work at the
96 ± 5 mm front, jack up the front frame until
a If the length of the cylinder is not correct, f r o n t ti r es c o m e s l i g ht l y o ff t h e
adjust it according to the steps 2 to 5. ground.
a When carrying out the work at the
rear, jack up the frame until either
center or rear tires come slightly off
the ground.
2) Remove cover (1).
3) Loosen oil level valve (2) slowly, and when
the nitrogen gas starts to come out, hold
the valve in that position.
a If oil spurts out from the valve to-
gether with the nitrogen gas, tighten
the valve slightly until no more oil
comes out and take time to release
the nitrogen gas slowly.
34 HM400-2
7) Remove suspension tools P2 to P5, and

then remove gas supply valve (3).
3 Air supply valve:
39.2 – 49.0 Nm {4 – 5 kgm}
4) Operate the hydraulic jack to lower the

frame slowly until the suspension cylinder
is retracted to the specified oil volume
length.
k Operate the hydraulic jack care-

fully to prevent the suspension cyl-
inder from being retracted too far
and suffering damage.
a Specified front oil volume length (a):
53 ± 3 mm
a Specified rear oil volume length (b):
66 ± 3 mm
3. Adjusting oil level

a Adjust the oil level after completing the
release of nitrogen gas.
1) Check that the suspension cylinder is the
specified oil volume length. 4. Charging with nitrogen gas
a Specified front oil volume length (a): a Charge with nitrogen gas after completing
53 ± 3 mm the adjustment of oil level.
a Specified rear oil volume length (b): 1) Remove the cap at the top of air supply
66 ± 3 mm valve (3).
k Operate the hydraulic jack care- 2) Connect suspension tools P7 to P12 as
fully. shown in the figure.
2) Remove oil level valve (2). a Connect joint P10 to the air supply
3) Remove the valve body from gas supply valve.
valve (3), and then install joint P6. a Before installing the regulator, blow
4) Install fitting P5 to joint P4, and then con- the filter at the mouthpiece thoroughly
nect hose P3 and pump P2. with nitrogen gas (min. 0.98 MPa {10
5) Operate pump P2 to release the gas from kg/cm²}) to prevent the entry of for-
the mounting port of oil level valve (2). eign materials.
a Keep sending oil to let the inside oil 3) Open valve [2] of nitrogen gas cylinder [1]
flow out from the mounting port until and check the pressure (internal pressure
the oil without air bubbles flow out. of the cylinder) indicated by gauge P12.
a Front cylinder oil charge amount a The indicated pressure must be
(reference): 6.0 l higher than the internal pressure of
a Rear cylinder oil charge amount the cylinder by at least 0.98 MPa {10
(reference): 4.2 l kg/cm²}.
6) Install oil level valve (2). a Cylinder internal pressure
3 Oil level valve: Front: 4.31 MPa {44.0 kg/cm²}
39.2 – 49.0 Nm {4 – 5 kgm} Rear : 1.18 MPa {12.0 kg/cm²}
HM400-2 35
4) Turn the handle of regulator P11 gradually 5. Adjusting cylinder length

to the left and set the pressure indicated in a Adjust the cylinder length after completion
gauge P13. of the nitrogen gas charging.
k Never charge the cylinders with a Carry out the adjusting of cylinder lengths
nitrogen gas at a pressure of more on a level road surface with the dump
than above specified pressure and body unloaded.
extend the cylinder fully to the 1) Move the machine about 15 m forward,
stroke end. and stop suddenly. Next, move in reverse
5) Operating valve P7 and the handle of joint and stop the machine suddenly at the
P10, charge the suspension cylinders with original point. Repeat this procedure 3 to 4
nitrogen gas. times. Finally, apply the retarder brake a
a Charge nitrogen gas into the left and little at a time and stop gently.
right cylinders at the same time. a Stop the machine as gently as possi-
6) When the length of the left and right cylin- ble using a retarder brake in order to
ders reaches the specified installed ease the sliding resistance (friction of
length, turn the handle of regulator P11 to packings and bushings) of cylinders.
the left to cease charging with nitrogen 2) Measure the installed length of the cylinder.
gas. a Installed length (a) of front cylinder:
a Installed length (a) of front cylinder: 153 ± 10 mm
153 ±10 mm Installed length (b) of rear cylinder:
Installed length (b) of rear cylinder: 96 ± 5 mm
96 ± 5 mm 3) If the installed length is too long, adjust by
7) Return the handle of joint P10 fully and discharging nitrogen gas through oil level
discharge the gas inside the hose by loos- valve (2).
ening the air bleeding plug of valve P7. a Slightly loosen the oil level valve and
8) Remove suspension tools P7 to P12. discharge an amount of gas which will
a Be careful not to lose the O-ring of air not make the cylinder move.
supply valve. a If gas is discharged to the point of
9) Install the cap at the top of air supply valve making the cylinder move, the
(3). installed length may become shorter
10) Install the covers of suspension cylinders. than the specified installation length.
4) After completing the adjustment, repeat
steps 1) and 2) above and check the cylin-
der length again.
5) Check for any leakage of gas from oil level
valve (2), air supply valve (3), and the cyl-
inder's gland area.
a Use soapy water to check for leakage
of gas.
36 HM400-2
Note 1: Testing after changing oil and gas

If the machine is operated after changing
the oil and gas, the gas merges with the oil
inside the cylinder up to the s a t u r a t i o n
point resulting in reducing the volume of
gas, and sometimes lessening the length
of the cylinder below the permissible val-
ue.
For this reason, test the installation length
of the cylinder in 48 hours time after
changing the oil and the gas, and a d j u s t
the gas if it is below the specified dimen-
sion.
Note 2: Testing cylinder length according to
change in ambient temperature
Since the gas in the suspension expands
or contracts according to the change in the
ambient temperature when the machine is
operating, the length of the cylinder
changes.
For this reason, in regions where there are
great temperature differences during the
year, carry out daily inspections and adjust
so that the installed length of the cylinder is
within the specified range.
HM400-2 37
Method of tilting cab up 1 1. Preparatory work:

1) Open the engine hood.
a Equipment for tilt cylinder 2) Take out a lock bar from the storage place
(Uselessness for external crane) at engine right side.
3) Remove 4 mounting bolts from each of the
left and right mounts at the front of cab.
I 792-454-1100 Pump assembly 4) Move pin (3) at the cab rear mount from
hole (4) to hole (5).
k When tilting the cab, observe the following
precautions to prevent a serious injury or
fatal accident caused by fall of the cab.
k To prevent interference between the cab
and the dump body, set the steering in a
st raight ah ea d pos ition a nd stop the
machine on the level ground.
k Lock the dump lever with the dump lever
lock knob.
k Turn the parking brake switch ON and
chock the wheels.
k Set the lock bar to the frame and lock front
and rear frame.
q Precautions in tilting cab 2. Tilting cab up
k When tilting the cab, check that the lock Method using tilt cylinder
lever is fixed securely. a External hydraulic pump assembly I is
k Do not start the engine while the cab is necessary.
tilted. 1) Disconnect cylinder hose (1) at quick cou-
k When it is obliged to start the engine for pler (Q)
.
testing etc., check that there is nobody
under the cab.
k Do not operate the gear shift lever or dump
lever.
k Do not give a large shock to the machine.
k Do not tilt the cab while it is loaded.
a When carrying out inspection and mainte-

nance work around the hydraulic pump or at
the top of the torque converter or transmission,
tilt the cab up to the rear of the machine as the
following.
a As there are the following two methods of tilt-
ing the cab up, select either method which
matches the operating site conditions.
q Method using tilt cylinder
a The external hydraulic pump assem-
bly I is necessary.
q Method using external crane
38 HM400-2
2) Exchange female quick coupler (F) to

male quick coupler (M) of external hydrau-
lic pump assembly.
a It is possible to get male quick cou-
pler (M) by removing it from (Q) on
the machine.
a Connecting adapter (Unit of male and
female qui ck c oupler ( Q) . Both
m a c h i n e s i d e a n d t o ol s i d e a r e
same.): 56B-54-16391 (Size of hose
connection end: RC 1/4)
3) Connect cylinder hose (1) to the external

hydraulic pump assembly.
4) Operate the external hydraulic pump and
tilt the cab up.
a Operate the pump within the specified
pressure.
Specified pump pressure:
20.6 – 34.3 MPa {210 – 350kg/cm²}
Method using external crane

1) Fit sling [1] to the hook of the cab mount .
2) Raise the cab (6) to tilt it up.
3. Fixing cab in position

1) Pull lock lever (2-1) and set lock bar (2)
with the care the direction of the lock bar
(2) at the front left of the cab. 4. Tilting cab down
2) Lower the cab (6) slowly and fix it in the a Tilt the cab down in the reverse order for
position. tilting the cab up.
k Check that the lock lever closes a After tilting the cab down, tighten the
and the cab (6) is held securely in mounting bolts and return the lock bar to
position by the lock bar (2). the storage place.
k When the cab is tilted up with the
tilt cylinder, release its hydraulic
pressure gradually, and lower the
cab slowly.
3) Remove the external pump or external
crane.
HM400-2 39
Testing and adjusting dump 3) Operate the dump lever with the engine
running at high idle and measure the oil
circuit oil pressure 1 pressure at RAISE relief or LOWER relief.
a Equipments for testing and adjusting dump cir-
cuit oil pressure
Q

1. Testing dump main relief oil pressure

a Since the dump main circuit uses the
same hydraulic pump (basic pressure)
together with the steering circuit and the 4) When the test is completed, remove the
steering circuit is structured to have a pri- instruments and restore to the original
ority over others, before inspecting it, it is condition.
necessary to check that the steering cir-
cuit pressure is normal. 2. Adjusting the dump main relief oil pressure
a Test the dump relief pressure at remote a If the dump main relief oil pressure is not
pressure pickup port (1). normal, adjust it with relief valve (2) of
hoist valve according to the following pro-
cedures.
1) Install hose [1] of hydraulic tester Q and

connect oil pressure gauge [2].
a If oil pressure gauges are of the ana- 1) While holding adjustment screw (3),
log type, use the one with rated pres- loosen locknut (4).
sure 40 MPa {400 kg/cm²}. 2) Turn adjustment screw (3) and adjust the
oil pressure.
a Adjustment screw:
a Change in pressure per 1 turn of ad-
justment screw:
19.6 MPa {200 kg/cm²}
3) While holding adjustment screw (3), tight-
en locknut (4).
3 Locknut: 29 – 39 Nm {3 – 4 kgm}
a After completing the adjustment,
2) Start the engine and operate the dump check the oil pressure again following
body up to either LOWER or RAISE stroke the procedure for the above test.
end.
40 HM400-2
3. Testing dump pilot relief oil pressure 5) When the test is completed, remove the
1) Remove the side cover of hydraulic oil instruments and restore to the original
tank. condition.
2) Remove oil pressure inspection plug (5).
4. Adjusting dump pilot relief oil pressure
a If the dump pilot relief oil pressure is not
normal, adjust it with relief valve (6)
3) Install the nipple of hydraulic tester Q and

hose [3], and connect oil pressure gauge
[2].
log type, use the one with rated pres- 1) Remove the cap.
sure 6 MPa {60 kg/cm²}. 2) While holding adjustment screw (7),
loosen locknut (8).
3) Turn adjustment screw (7) and adjust the
oil pressure.
a Adjustment screw:
a Change in pressure per 1 turn of ad-
justment screw:
1.8 MPa {18.6 kg/cm²}
4) While holding adjustment screw (7), tight-
en locknut (8).
3 Locknut: 40 Nm {4.1 kgm}
4) Start the engine and with the engine run-
a After completing the adjustment,
ning at high idle, measure the fuel pres-
check the oil pressure again following
sure while holding the dump lever at
the procedure for the above test.
neutral position.
5) Install the cap.
HM400-2 41
Adjusting body positioner 4) Install mounting bolt (2).

5) Tighten locknut. (1).
sensor 1 6) Following to the testing procedure above,
a If the body positioner rod was once discon- verify the input voltage is within the normal
nected and connected again or the body posi- range.
tioner sensor was once removed and installed (Serial number: – 2461)
again, test and adjust the body positioner sen-
sor according to following procedures.
1. Testing the sensor input voltage

machine monitor to the real-time monitor-
ing function (REAL-TIME MONITOR) dis-
play of the service mode.
q Monitoring system: TRANSMISSION
q Monitoring code:
34603 (BODY POSITION)
a For the operation method, see "Spe-
cial functions of machine monitor".
(Serial number: 2462 and up)

3) Operate the dump lever and check the
3. System calibrating operation
monitoring voltage when the dump lever is
1) Start the engine and raise the hydraulic oil
operated up to the LOWER and RAISE
temperature to 80 – 90 °C.
stroke ends.
2) While running the engine at low idle, lower
q Serial number: – 2461
the dump body to the lower stroke end
a LOWER stroke end: 0.40 – 0.60 V
and keep the dump lever in the "float" po-
a RAISE stroke end: 4.00 – 4.70 V
sition for at least 5 seconds.
q Serial number: 2462 and up
a Check that the body pilot lamp is
a LOWER stroke end: 0.36 – 0.44 V
turned OFF.
a RAISE stroke end: 4.00 – 4.70 V
3) While running the engine at low idle, raise
the dump body to the raise stroke end and
2. Adjusting link length
keep the dump lever in the "raise" position
a If the monitoring voltage is not within the
for at least 5 seconds.
normal range, adjust the link length
4) While running the engine at low idle, lower
the dump body to the lower stroke end.
1) Loosen locknut (1).
5) While running the engine at high idle,
2) Remove mounting bolt (2).
raise the dump body to the raise stroke
3) Turn rod end (3) and adjust the link length.
end and then lower the engine speed to
a Input voltage:
low idle and set the dump lever to the
q Becomes lower when the link is
"lower" position. After the dump body
lengthened.
starts lowering, return the dump lever to
q Becomes higher when the link is
the "float" position and lower the dump
shortened.
body to the lower stroke end.
a Change in voltage per 1 turn of rod
end: Approx. 0.04V
42 HM400-2
a Repeat the above operation 5 – 10

times.
6) While running the engine at high idle,
raise the dump body to the raise stroke
end and then keep the engine speed at
high idle and set the dump lever to the
"lower" position. After the dump body
starts lowering, return the dump lever to
the "float" position and lower the dump
body to the lower stroke end.
a Repeat the above operation 5 – 10
times.
HM400-2 43
Adjusting length of spring in body Handling of voltage circuit of

heating spherical joint 1 engine controller 1
a If the body heating bellows does not move 1. Disconnecting or connecting operation of the
smoothly while the machine is steered or oscil- connector between the engine controller and
lated, or if the bellows is replaced, adjust the the engine shall be performed only when the
length of the spring according to the following starting switch is in the OFF position.
procedure.
2. Do not start the engine while the T adapter is
1. Adjust length (a) of spring (1) to the specified ins er ted or c onnec ted to the c onne ctor
dimension. between the engine controller and the engine
a Standard length (a) of the spring: for diagnosis.
60 ± 1 mm a You may turn the starting switch to the
a Both front side and rear side are to be OFF or ON position but must not turn it to
adjusted in the same way. the START position.
a Check that the dispersion of dimension (b)
of each stud is 1 mm or less.
a Standard dimension (b) of stud:
58 mm (reference) Adjusting transmission
controller 1
a After any of the following operations, adjust the
transmission in order to tune the feeling of
transmission and its controller.
q The transmission has been overhauled or
replaced.
q The transmission control valve has been
repaired or replaced.
q If the transmission controller is replaced.
q Power train speed sensor has been repaired or
replaced.
q The transmission oil temperature sensor has
been repaired or replaced.
2. When the adjustment is completed, check the q The transmission oil filter has been clogged
following points. abnormally and repaired.
1) There is no leakage of exhaust gas. a For the adjusting operation of the transmission,
2) The spherical joint turns smoothly without use the service function of the machine moni-
any sticking or prying. tor.
a For the details of the operation method, see
"Special functions of machine monitor".
44 HM400-2
Method for emergency escape at electrical system failure 1

If any problem occurs in the electrical system of the engine or transmission control system, it may disable the
engine to start or the machine to move off.
If such a problem occurs, temporarily restore the engine or transmission electrical system to move the
machine to a safe place, then carry out regular troubleshooting.
1. When any problem occurs in the engine control system and the engine cannot be started:
a Decide the escape method according to the following flowchart.
a Refer to "Special functions of machine monitor" for the method of checking the failure code.
Note: If the engine cannot be started and the machine is to be towed, release the parking brake temporarily
referring to "Method for emergency release of parking brake", since it cannot be released by operating
the switch.
HM400-2 45
2. When any problem occurs in the transmission control system and the machine cannot be
started:
a Check the failure code, and determine an adequate escape procedure from following table.
a Refer to "Special functions of machine monitor" for the method of checking the failure code.
Failure Condition when Lever position for speed range to
Escape method Remarks
code failure occurs move off after escape operation
1500L0 Occurrence condition 2 Escape procedure 2 — Occurrence condition 1:
Gear speed remains fixed and will
15G0MW Occurrence condition 7 Escape procedure 1 D – 1: F2 speed
not shift from that position when
15H0MW Occurrence condition 7 Escape procedure 1 D – 1: F1 speed, R1 – R2: R1 speed restarting.When gear shift lever is
15J0MW Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed shifted to N, transmission is set to
neutral.
15K0MW Occurrence condition 7 Escape procedure 3 D – 1: F3 speed, R1 – R2: R2 speed
15L0MW Occurrence condition 7 Escape procedure 3 D – 1: F2 speed, R1 – R2: R1 speed Occurrence condition 2:
Transmission suddenly shifts to
15M0MW Occurrence condition 7 Escape procedure 3 D – 1: F2 speed, R1 – R2: R1 speed
neutral while traveling. And after
15SBL1 Occurrence condition 7 Escape procedure 1 R1 – R2: R1 speed machine is stopped, operating lever
15SBMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed does not shift the transmission from
neutral and machine can not move
15SCL1 Occurrence condition 7 Escape procedure 1 D – 1: F2 speed off.
15SCMA Occurrence condition 7 Escape procedure 1 D – 1: F1 speed, R1 – R2: R1 speed
Occurrence condition 3:
15SDL1 Occurrence condition 7 Escape procedure 1 D – 1: F1 speed
Transmission suddenly shifted to
15SDMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed neutral while traveling.
15SEL1 Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
15SEMA Occurrence condition 7 Escape procedure 1 D – 1: F3 speed, R1 – R2: R2 speed
Even if the lever is operated after
15SFL1 Occurrence condition 7 Escape procedure 1 D – 1: F3 speed, R1 – R2: R2 speed the engine is started, the transmis-
sion stays in neutral and the
15SFMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
machine cannot be started.
D – 1: F5 speed,
15SGL1 Occurrence condition 7 Escape procedure 1
R1 – R2: R3 or equivalent speed Occurrence condition 5:
15SGMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed Response of lever became abnor-
mal and lever operation did not
15SJMA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
work. When lever was forced to
Normal traveling is possible if display operate, transmission shifted to
DAQ0KK Occurrence condition 1 Escape procedure 5
returns to normal (Note 1) neutral.
Normal traveling is possible if display
DAQ2KK Occurrence condition 1 Escape procedure 4 Occurrence condition 6:
returns to normal (Note 1)
Speed range remains fixed, and
DAQ9KQ Occurrence condition 4 Escape procedure 6 — when machine moves off again, the
Normal traveling is possible if display transmission does not shift from the
DAQRKR Occurrence condition 2 Escape procedure 5 fixed speed range. If lever is posi-
tioned at N, transmission shifts to
DAQRMA Occurrence condition 4 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
neutral, and after that, it can not be
DB2RKR Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed shifted.
DDTHKA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed
DDTJKA Occurrence condition 1 Escape procedure 1 D – 1: F1 speed Gear speed is fixed with appropri-
DDTKKA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed ate clutches applied for the travel. If
appropriate clutches are not avail-
DDTLKA Occurrence condition 1 Escape procedure 1 D – 1: F3 speed, R1 – R2: R2 speed
able for the travel, transmission
D – 1: F5 speed, shifts to neutral. If lever is posi-
DDTMKA Occurrence condition 1 Escape procedure 1
R1 – R2: R3 or equivalent speed tioned at N, transmission shifts to
neutral.
DDTNKA Occurrence condition 1 Escape procedure 1 R1 – R2: R1 speed
Normal traveling is possible if display Note 1:
DF10KA Occurrence condition 5 Escape procedure 7
returns to normal (Note 1) Even when the machine condition is
Normal traveling is possible if display restored after a failure, the neutral
DF10KB Occurrence condition 5 Escape procedure 7 condition is maintained until the
lever is returned to the N position.
DLF1KA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
DLF1LC Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
DLF2KA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
46 HM400-2
Failure Condition when Lever position for speed range to

Escape method Remarks
code failure occurs move off after escape operation
DLF2LC Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1 * Refer to description on previous
pages
DLT3KA Occurrence condition 6 Escape procedure 3 D – 1: F2, R1 – R2: R1
DXH1KA Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH1KB Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH1KY Occurrence condition 1 Escape procedure 1 D – 1: F2, R1 – R2: R1
DXH2KY Occurrence condition 7 Escape procedure 1 D – 1: F2
DXH3KY Occurrence condition 7 Escape procedure 1 D – 1: F1
DXH6KY Occurrence condition 7 Escape procedure 1 D – 1: F5, R1 – R2: R3 or equivalent
DXH7KA Occurrence condition 7 Escape procedure 1 D – 1: F2
DXH7KB Occurrence condition 7 Escape procedure 1 D – 1: F2
DXH7KY Occurrence condition 7 Escape procedure 1 R1 – R2: R1
Escape procedure 1:
1) Stop traveling and return the shift lever to N position.
2) Operate the gear shift lever again and move the machine off.
a When operating the gearshift lever, release the accelerator pedal.
a Shift lever operation: N o D – 1, or N o R1 – R2
Escape procedure 2:
Tow the machine.
a If the engine cannot be started and the machine is to be towed, release the parking brake temporarily
referring to "Method for emergency release of parking brake", since it cannot be released by operating
the switch.
Escape procedure 3:
1) Stop traveling and return the shift lever to N position.
2) Connect and disconnect the emergency escape connectors A1 (female) and A2 (male) temporarily, and
switch to the emergency escape mode.
a Connectors A1 and A2 are installed in front of the transmission controller.
a Connect and disconnect the connectors with the starting switch ON or with the engine started.
3) Operate the gear shift lever and move the machine off again.
a When operating the gearshift lever, release the accelerator pedal.
a Shift lever operation: N o D – 1, or N o R1 – R2
a The emergency escape mode is maintained until the starting switch is turned OFF.
HM400-2 47
Escape procedure 4:
Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
q Circuit breaker: No.64 (80A), No.65 (80A)
q Fuse: BT3-No.14 (10A)
Escape procedure 5:
Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
q Circuit breaker: Inside battery housing (30A)
Escape procedure 6:
Reset the model selection setting, then reset the selection of options.
a To check the model and option selection setting, refer to the section "Setting and adjusting of each
equipment".
Escape procedure 7:
Check the fuse, and if it is normal, replace the gear shift lever.
48 HM400-2
HM400-2 49

© 2009 KOMATSU
All Rights Reserved
50 HM400-2
SEN00918-03

HM400-2

HM400-2 2001 and up

Setting and adjusting various equipments ...................................................................................................... 2
Special function of machine monitor ..............................................................................................................11
How to start operation of KOMTRAX terminal .............................................................................................. 56
Lamp display of KOMTRAX terminal ............................................................................................................ 61
Pm Clinic check sheet................................................................................................................................... 64
Initial setting of payload meter ...................................................................................................................... 67
HM400-2 1
Setting and adjusting various equipments 1

Setting and adjustment items which are required after the replacement, disassembly and assembly,
or additional installation of controller or sensor has been performed.
a When the replacement, disassembly and assembly, or additional installation of the equipments and
components shown below has been performed, carry out the necessary setting and adjusting.
Replaced, disassembled
and assembled, and addi-
Necessary setting and adjustment items
tionally installed equip-
ments and components
• 1-1. Setting of model selection
• 1-2. Setting of option selection
• 1-3. OFF setting of maintenance monitor (corrosion resistor)
Machine monitor • 2-1. Deletion of electrical system failure history information (Refer to *2-1)
• 3-1. Setting of service meter (Refer to *3-1)
• 3-1. Setting of integrated odometer (Refer to *3-1)
• 3-2. Setting of integrated reverse odometer (Refer to *3-2)
• 2-2. Adjusting a transmission ECMV electric current (Refer to *2-2)
Transmission unit
• 2-3. Reset of transmission initial learning and implementation of learning (Refer to *2-2)
• 1-2. Setting of option selection
Transmission controller • 2-2. Adjusting a transmission ECMV electric current (Refer to *2-2)
• 2-3. Reset of transmission initial learning and implementation of learning (Refer to *2-2)
• 2-1. Deletion of electrical system failure history information (Refer to *2-1)
Transmission ECMV • 2-2. Adjusting a transmission ECMV electric current (Refer to *2-2)
solenoid • 2-3. Reset of transmission initial learning and implementation of learning (Refer to *2-2)
Retarder controller • 1-2. Setting of option selection
• 2-1. Deletion of electrical system failure history information (Refer to *2-1)
Body positioner sensor
• 2-3. Adjusting body positioner sensor (Refer to *2-3)
Body positioner rod
KOMTRAX • 2-4. How to start operation of KOMTRAX terminal
Optional equipment • 1-2. Setting of option selection
* 2-1: As for the setting and adjustment procedure, refer to "Special function of machine monitor" ([9] Electri-
cal system failure history display function)
* 2-2: As for the setting and adjustment procedure, refer to "Special function of machine monitor". ([14]
Adjustment function)
* 2-3: As for the setting and adjustment procedure, refer to the section of "Adjusting body positioner sensor".
* 2-4: As for the setting and adjustment procedure, refer to the section of "How to start operation of
KOMTRAX terminal".
* 3-1: As for the setting and adjustment procedure, refer to the service news (AT06310).
* 3-2: As for the setting and adjustment procedure, refer to the service news (AT06310)..
2 HM400-2
1-1. Setting of model selection 4) Displaying service menu selection screen

1. Switching to service mode After confirming all ID's of 4 digits, display
1) Confirming the screen display the service menu selection screen in the
Check that the machine monitor is in oper- service mode.
ator mode and the screen is displaying a By inputting and determining the ID
either the "service meter and integrated once, it will be effective until the start-
odometer", "action code" or "failure code". ing switch is turned off.
2) Displaying ID input screen
Press the following 2 switches at the same
time for longer than 5 seconds to display
the ID input screen.
q [t] switch and [<] switch
a If the switch is pressed for longer than
5 seconds, the character display sec-
tion becomes blank. After confirming
this condition, release the switch.
2. Selecting and determining service menu

1) When pressing the [>] switch or [<] switch
in the service menu selection screen, the
service menu is displayed endlessly in the
order shown in the below table, so select
the model selection function (MACHINE).
q [>]: To proceed to next service menu.
q [<]: To return to previous service menu.
a Displayed service menu:
3) Input and determination of ID
After displaying ID input screen, operate Display Function
[>], [<], [U], and [t] switch to input 4 dig- ELECTRIC FAULT
Electrical system failure history
its ID. display function
a ID: 6491 Mechanical system failure history
MACHINE FAULT
display function
q [ > ]: Number at the cursor increases.
[ < ]: Number at the cursor decreases REAL-TIME
q Real-time monitoring function
MONITOR
q [U]: Number at the cursor is deter-
CYLINDER
mined CUT-OUT
Reduced cylinder mode
q [t]: Cursor moves to left end or the
NO INJECTION No injection cranking function
display returns to operator mode
TUNING Adjusting function
screen.
MAINTENANCE Filter and oil replacement time setting
a If the ID input screen is left without MONITOR function
switch operation for longer than 60
OPERATION INFO Operation information display function
seconds, it automatically returns to
OPTIONAL
the operator mode screen. SELECTION
Option selection function
MACHINE Model selection function
Initialize function
INITIALIZE
(exclusive function for factory)
a As for the use of the service menu,

besides model selection function,
option selection function, and filter
and oil replacement time setting func-
tion (part of function), refer to the sec-
tion of "Special function of machine
monitor".
a *
In the " " part, the model presently
set is displayed.
HM400-2 3
a Even if the model presently set is cor- 2) After selecting the model in the model
rect, be sure to carry out the setting selecting screen, determine the model by
newly. pressing the [U] switch.
q [U]: Determine the setting.
q [ t]: To cancel the setting
a The below figure shows the example
that HM400-2 has been selected.
2) After selecting the model selection func-

tion, press [U] switch for longer than 5
seconds and display the model selection
setting screen.
q [U]: Conduct the service menu.
4. Storing data in controller
a Press [U] switch for longer than 5
1) After determining the model selection set-
seconds, otherwise it will not change
ting, check that the display automatically
to model selection setting screen.
returned to the service menu screen and
a In the model selection setting screen,
the selected model is surely displayed.
display only the model to be set at the
[*] part.
2) Turn the starting switch OFF and keep

that condition for longer than 15 seconds.
3. Selecting and setting of model
a Unless the starting switch is turned off
for longer than 15 seconds, the new
in the model selection setting screen, the
data is not memorized in the control-
model which can be set is displayed end-
ler.
lessly in the order shown in the below
3) Turn the starting switch ON again.
table, so select the applied model.
a After this operation the model setting
q [>] switch: To proceed to next model
becomes effective.
q [<] switch: To return to previous model
a Displayed model:
5. Carrying out option setting
Display Model If once carrying out the model selection set-
HM400 HM400-2 ting, all setting of option selection is reset, so
HM400TN HM400-2 (Tunnel specifications) continue to carry out the setting of option
HM350 HM350-2 selection.
HM350TN HM350-2 (Tunnel specifications) a Refer to section "1-2. Setting of op-
tion selection".
HM300 HM300-2
HM300TN HM300-2 (Tunnel specifications)
4 HM400-2
1-2. Setting of option selection

a Item list of option selection function
Default
Check item Code Display Content of selection
setting
Left-and-right
01 LR DIF LOCK ADD Select [NO ADD] if not applied.
differential lockup
Accelerator
02 ACC RETARD NO ADD Select [ADD] if applied.
connected retarder
— 05 — NO ADD Fixed to "NO ADD"
Set speed compensation value according to the tire size.
Select as below according to tire size.
• HM400/400TN-2 29.5-R25 (standard): 0%
Tire size
08 TIRE SIZE 0% If the display of the speedometer has an error, adjust it using this
compensation
item.
• Each time it is raised by 1%, the display increases by 1% com-
pared to the display when it is 0%.
Maintenance
10 SENSOR NO ADD Always select "NO ADD"
sensor
Select economy
12 E1 MODE ADD Always select [ADD].
mode
Select a unit as follows.
Selection of unit SPEED • When using MPH: MPH
13 MPH
(MPH or km/h) (UNIT) • When using km/h: km/h
a This item is not displayed for SI specification.
1. Switching to service mode a Press [U] switch for longer than 5

Switch to the service mode by referring to "1-1. seconds, otherwise it will not change
Setting of model selection". to optional item selection screen.
a The setting status of that optional
2. Selecting and carrying out service menu item is displayed at the left of the
1) Select the optional selection function lower row.
(OPTIONAL SELECTION) in the service q ADD: Option is set.
menu selection screen by referring to "1-1. q NO ADD: Option is not set.
Setting of model selection".

2) After selecting the optional selection func- in the option item selection screen, the
tion, press [U] switch for longer than 5 optional item is displayed endlessly in the
seconds and display the setting screen for order shown in the below table, so select
the optional item selection. the necessary item.
q [U]: Conduct the service menu. q [>]: To proceed to next option item.
q [>]: To return to previous option item.
HM400-2 5
a Displayed option items: 3. Setting of left-and-right differential lock-up

(01: LR DIF LOCK)
Display Check item
1) Select the left-and-right differential lock-up
01: LR DIF LOCK Left-and-right differential lockup (01: LR DIF LOCK) in the optional item
02: ACC RETARD Accelerator connected retarder selection screen.
05: — — a The present setting status is displayed
at the left of the lower row. (ADD:
06: — —
Option is set. NO ADD: Option is not
08: TIRE SIZE Tire size compensation set.)
10: SENSOR Maintenance sensor
11: — —
12: E1 MODE Select economy mode
13: SPEED (UNIT) Selection of unit (Do not use.)
a Perform after checking that the model

has been set.
a Always check all the items.
a Settle the first item by pressing the
[U] switch twice, even if the current
setting is correct (to transmit the infor-
mation to the other controllers).
a After setting, be sure to turn the start-
2) After confirming the installation condition
ing switch OFF and wait for 15 sec-
of the left-and-right differential lock-up and
onds to settle the memory of each
the setting status on the screen, press the
controller.
[U] switch and determine the setting.
q [U]: To change setting.
(Display is changed.)
q [t]: To return to optional item selec-
tion screen.
q ADD: To set option.
q NO ADD: Not to set option.
a If the setting is once determined by
pressing the [U] switch, it is effective
even after the screen is terminated.
6 HM400-2
4. Setting of accelerator connected retarder 5. Setting of tire size compensation (08: TIRE
(02: ACC RETARD) SIZE)
1) Select the accelerator connected retarder 1) Select the tire size compensation (08:
(02:ACC RETARD) in the optional item TIRE SIZE) in the option item selection
selection screen. screen.
a The present setting status is displayed a The present compensation value is
at the left of the lower row. (ADD: displayed at the left of the lower row.
Option is set. NO ADD: Option is not (***%: Rate of change from standard
set.) tire)
2) After confirming the installation condition 2) For changing the compensation value,
of the left-and-right differential lock-up and press the [U] switch to display the com-
the setting status on the screen, press the pensation value input screen.
[U] switch and determine the setting. q [U]: To change compensation value.
q [U]: To change setting. 3) After displaying the compensation value
(Display is changed.) input screen, operate each of the switches
q [t]: To return to optional item selec- [>], [<], [U] and [t] to input the compen-
tion screen. sation value directly.
q ADD: To set option. q [>]: To switch the cursor symbol (+/-);
q NO ADD: Not to set option. To increase number.
a If the setting is once determined by q [<]: To switch the cursor symbol (+/-);
pressing the [U] switch, it is effective To decrease number.
even after the screen is terminated. q [U]: To determine compensation val-
ue.
q [t]: Cursor moves to left end / To re-
turn to optional item selection
screen.
a The compensation value at the plant
before shipment is [+/- 00%] (In case
of inputting 00, +/- does not matter.)
a The compensation value can be input
within the range of [-10 % – +10 %].
HM400-2 7
6. Setting of maintenance sensor (10: SENSOR) 7. Setting of economy mode (12: E1 MODE)
1) Select the maintenance sensor (10: SEN- 1) Select the economy mode (12: E1 MODE)
SOR) in the optional item selec tion in the optional item selection screen.
screen. a The present setting status is dis-
a The present setting status is displayed at the left of the lower row.
played at the left of the lower row. (ADD: Option is set. NO ADD: Option
(ADD: Option is set. NO ADD: Option is not set.)
is not set.)
2) After confirming the setting status on the

2) After confirming the installation condition screen, press the [U] switch and deter-
of the maintenance sensor and the setting mine the setting.
a Always set [ADD] for this item.
status on the screen, press the [U] switch
and determine the setting.
(Display is changed.)
q [t]: To return to optional item selec-
(Display is changed.) tion screen.
q [t]: To return to optional item selec- q ADD: To set option.
tion screen. q NO ADD: Not to set option.
q ADD: To set option. a If the setting is once determined by
q NO ADD:Not to set option. pressing the [U] switch, it is effective
a If the setting is once determined by even after the screen is terminated.
pressing the [U] switch, it is effective
even after the screen is terminated.
8. Storing data in controller

1) Check that the setting for all items has
been completed in the sub menu screen
for the optional item selection function.
2) Turn the starting switch OFF and keep
that condition for longer than 15 seconds.
a Unless the starting switch is turned off
for longer than 15 seconds, the new
data is not memorized in the controller.
3) Turn the starting switch ON again.
a After this operation the option setting
becomes effective.
8 HM400-2
1-3. OFF setting of maintenance monitor (corro- a Displayed maintenance items:

sion resistor)
Display Maintenance items and functions
1. Switching to service mode
Switch to the service mode by referring to "1-1. 41:FUEL P FILT Fuel pre filter
Setting of model selection". 01:ENG OIL Engine oil
02:ENG FILT Engine oil filter
2. Selecting and carrying out service menu 12:TM OIL Transmission oil
1) Select the filter and oil replacement time 13:TM FILT Transmission oil filter
setting function (MAINTENANCE MONI-
03:FUEL FILT Fuel main filter
TOR) in the service menu selec tion
screen referring to "1-1. Setting of model 06:CORR RES Corrosion resistor
selection". 17:BK OIL Brake oil
14:BK OIL FILT Brake oil filter
16:BK C FILT Brake cooling oil filter
04:HYD FILT Hydraulic oil filter
11:DIFF OIL Differential oil
08:FNL OIL Final drive oil
10:HYD OIL Hydraulic oil
INTIALIZE Setting default value for all items
ALL ITEMS Setting validity or invalidity for all items
a As for the use of maintenance items

besides the corrosion register, refer to
th e s ec ti on "Spe ci al fu nc tio n o f
machine monitor".
3. Displaying and selecting of maintenance item
1) While the filter and oil replacement time
setting function is selected, display the
maintenance item selection screen by
pressing the [U] switch.
4. OFF setting of corrosion register item

1) With the corrosion register selected, press
the [U] switch and display the interval
change screen.
q [U]: To carry out interval change.
in the maintenance item selection screen,
the maintenance item is displayed end-
lessly in the order shown in the below
table, so select the corrosion register (06:
CORR RES).
q [>]: To proceed to next maintenance
item.
q [<]: To return to previous mainte-
nance item.
HM400-2 9
2) After displaying the interval change

screen, press the [>] or [<] switch further
and display the setting screen for validity
or invalidity.
q [>]: Change the displayed screen
q [<]: Change the displayed screen
a If the present setting is ON, the
screen displays as above, and if the
present setting is OFF, it displays as
below.
a The default setting of the machine
monitor is ON (above).
a If the present setting is ON (above),
carry out the further operation to
change the setting to OFF.
a If the present setting is OFF (below),
press the [t] switch to complete the
setting.
3) In order to change the present setting

from ON to OFF, press the [U] switch to
display the setting change screen.
q [U]: Change setting.
4) After displaying the setting change
screen, operate [>], [<], and [t] switch to
determine OFF setting.
q [<]: Select YES (move cursor)
q [>]: Select NO (move cursor)
q [t]: To determine selection.
10 HM400-2
Special function of machine monitor 1
t Normal function and special function of machine monitor

The machine monitor is equipped with normal and special functions, and displays various types of informa-
tion to the character display at the center of the monitor section.
Some items are displayed automatically and the others are displayed according to the operation of the
switches for the machine monitor.
1) Normal function: Operator mode
With this function, an operator can view and change the items displayed normally or displayed by the
operation of the switches.
2) Special function: Service mode
With this function, a serviceman can display and change the displayed items by the specified switching
operation for testing, adjusting, setting and troubleshooting.
Operator mode Service mode
Service meter and integrated odometer display
1 9 Electrical system failure history display function
function (Default)
Dozing counter display function
2 10 Mechanical system failure history display function
(When option is selected)
3 Integrated reverse odometer display function o 11 Real-time monitoring function
4 Replacement time display function of filter and oil 12 Reduced cylinder mode
5 Phone No. input function 13 No injection cranking function
6 Language selection function 14 Adjusting function
7 Action code display function 15 Filter and oil replacement time setting function
8 Failure code display function 16 Operation information display function
17 Option selection function
18 Model selection function
19 Initializing function (exclusive function for factory)
HM400-2 11
Function and flow of each mode
Operator mode
Dozing counter display function

2 (When option is selected)
Integrated reverse odometer

Service meter and 3 display function
1 integrated odometer display
function (Default)
Replacement time display
4
function of filter and oil
5 Phone No. input function
(Automatic) Service meter and integrated

6 Language selection function 1
odometer display function
7 Action code display function 8 Failure code display function
& + (ID input: 6491)

Service mode
9 Electrical system failure history

display function
Mechanical system failure

10 history display function
11 Real-time monitoring function Monitoring system and function:

5 items
12 Reduced cylinder mode
13 No injection cranking function
14 Adjusting function Adjustment items: 2 items
15 Filter and oil replacement time Maintenance items and functions:

setting function 16 items
16 Operation information display function Operation information screens: 3 screens
17 Option selection function Option items: 9 items
18 Model selection function
19 Initializing function (exclusive function for factory)
Electrical system failure history

9 display function
12 HM400-2
Operator mode Character display portion

a No. 2 – No. 6 is displayed endlessly by follow- 16 characters can be displayed on each upper and
ing the switch operation. lower row of the character display section, and
a When a failure occurs, the screen changes depending on the contents displays the combina-
automatically to No. 7 regardless of the dis- tion of the next figures, letters, and symbols.
played screen. 1) Arabic numbers: 1, 2, 3, . . .
a If the switch is not operated for over 30 sec- 2) Small letters: a, b, c, . . .
onds regardless of the display screen, the 3) Capital letters: A, B, C, . . .
screen automatically; 4) Katakana: A, I, U, . . . (Only for Japanese dis-
q Changes to No. 1. play)
(If malfunction has not occurred.) 5) Symbols: @, ?, $, . . .
q Changes to No. 7. 6) Special letters:
(If malfunction has occurred.)
a After moving from No. 8 to No. 1 by the switch
operation, if no switch operation is performed
for longer than 10 seconds, then it automati-
cally moves to No. 7.
Service mode
a No. 9 – No. 19 is displayed endlessly by follow-
ing the switch operation.
a By inputting and determining the ID once, it will
be effective until the starting switch is turned
off.
Control switch section

All the display operation of the machine monitor is
operated by the machine monitor mode selector
switches (1) and (2).
Each switch of [U], [t], [>], [<] is assigned to the
following function.
1) U: Determine and execute
2) t : To cancel, release, and determine
(only YES and NO screen)
3) > : To right, to next, to proceed, to increase
(only when inputting Arabic numbers)
4) < : To left, to previous, to return, to decrease
(only when inputting Arabic numbers)
HM400-2 13
t Operator mode (Outline) [3] Integrated reverse odometer display func-

tion
[1] Service meter and integrated odometer dis- Machine monitor displays the integrated reverse
play function odometer by operating the switch.
When turning the starting switch ON, the speed a For details, see operation manual.
meter and integrated odometer are displayed in the
upper and lower row respectively.
a For details, see operation manual.
[4] Filter and oil replacement time display

function
1. Replacement time display of filter and oil (dis-
[2] Dozing counter display function played automatically)
(When option is selected) When the replacement interval for the various
Display the dozing counter by operating the filters or oils approaches, the machine monitor
machine monitor switch. automatically displays the information to
a Dozing counter is displayed only when the remind an operator of maintenance.
option selection is set to be effective in the ser-
vice mode.
a For details, see operation manual.
14 HM400-2
2. Reset of replacement time (selection menu) [6] Language selection function

The machine monitor can reset the interval Display language of the machine monitor can be
time by operating the switch, if various filters selected with the switch operation.
and oils maintenances are finished. a The Service mode function is not included in
a For details, see operation manual. the display selection function, therefore always
a Replacement interval time setting can be displayed in English.
operated by the filter and oil replacement a For details, see operation manual.
time setting function in the service mode.
[7] Action code display function

[5] Phone No. input function When abnormal situations occur, the machine mon-
Phone No. set in the machine monitor can be input- itor automatically displays the action code depend-
ted, corrected, and released by the switch opera- ing on the extent of the abnormality in order to
tion. remind the operator of proper remedy.
a Phone No. is displayed together with "CALL" a Below figure shows the example of displaying
when action code "E03" is displayed. action code "E03" and "CALL + phone No."
a For details, see operation manual. alternately.
a "CALL + phone No." is not displayed if the
action code "E01" or "E02" is displayed.
HM400-2 15
a Action code and remedy requested for an operator

Action code CALL + phone No. Remedy requested for operator
E01 None • Carry out test and maintenance when operation is finished or operator is changed.
• If related to an over run is displayed:Travel keeping the engine speed and machine
speed down.
E02 None
• If related to an overheat is displayed:Stop machine and keep engine with no-load
medium speed running.
E03 Yes • Stop the engine and machine immediately and contact the service personnel.
16 HM400-2
[8] Failure code display function

By pressing the [>] switch once while the action
code is displayed on the machine monitor, the
present failure code is displayed.
q [>]: To display failure code.
a The failure codes which have been detected in

the past are separated into electrical and
mechanical systems and recorded as failure
history (refer to service mode for a detail).
a If there are several failures, other failure codes
are displayed by pressing the [>] switch.
a After displaying all the failure codes by press-
ing the [>] switch, press [>] switch further to
return to the service meter and integrated
odometer display screen.
Press the [>] switch again, and the failure code
is displayed from the beginning.
a If there is no switch operation for longer than
10 seconds in the service meter and integrated
odometer display screen, it automatically
switches to the action code display screen.
a The following information is displayed in the
service code display function.
A: Failure code (4-digits device code + 2-digits
symptom code)
B: Controller code
MON: Machine monitor
ENG: Engine controller
TM: Transmission controller
BK: Retarder controller
C: Trouble occurring system
a Refer to "Failure code table" for details of dis-
played failure codes.
a Be careful of the partial difference in the dis-
played information for the failure code display
function and the failure history display function
(service mode).
HM400-2 17
Failure code table

Failure Applicable Action History
Failure contents
codes equipments code classification
1500L0 Detecting dual engagement TM E03 Mechanical system
15B0NX T/M oil filter clogging TM E01 Mechanical system
15F0KM R o F gear shift abuse 1 TM – Mechanical system
15F0MB R o F gear shift abuse 2 TM – Mechanical system
15F7KM T/M forward clutch abuse TM – Mechanical system
15G0MW R clutch system failure (Slip is detected) TM E03 Electrical system
15G7KM T/M reverse clutch abuse TM – Mechanical system
15H0MW Hi clutch system failure (Slip is detected.) TM E03 Electrical system
15J0MW Lo clutch system failure (Slip is detected.) TM E03 Electrical system
15K0MW 1st clutch system failure (Slip is detected.) TM E03 Electrical system
15L0MW 2nd clutch system failure (Slip is detected.) TM E03 Electrical system
15M0MW 3rd clutch system failure (Slip is detected.) TM E03 Electrical system
15SBL1 R clutch pressure control valve failure TM E03 Electrical system
15SBMA R clutch pressure control valve failure TM E03 Electrical system
15SCL1 Hi clutch pressure control valve failure TM E03 Electrical system
15SCMA Hi clutch pressure control valve failure TM E03 Electrical system
15SDL1 Lo clutch pressure control valve failure TM E03 Electrical system
15SDMA Lo clutch pressure control valve failure TM E03 Electrical system
15SEL1 1st clutch pressure control valve failure TM E03 Electrical system
15SEMA 1st clutch pressure control valve failure TM E03 Electrical system
15SFL1 2nd clutch pressure control valve failure TM E03 Electrical system
15SFMA 2nd clutch pressure control valve failure TM E03 Electrical system
15SGL1 3rd clutch pressure control valve failure TM E03 Electrical system
15SGMA 3rd clutch pressure control valve failure TM E03 Electrical system
15SJMA L/U clutch pressure control valve failure TM E03 Electrical system
Inter axle differential lock-up clutch pressure control valve failure
15SKMA TM E01 Electrical system
2A62L1 Front wheels differential lockup control valve system failure BK E01 Electrical system
2A62LH Front wheels differential lockup control valve system failure BK E01 Electrical system
2B62L1 Rear wheels differential lockup control valve system failure BK E01 Electrical system
2B62LH Rear wheels differential lockup control valve system failure BK E01 Electrical system
2C4MNX Retarder cooling filter clogging MON E01 Mechanical system
2F00KM Dragging of parking brake TM – Mechanical system
2G42ZG Decrease of accumulator oil pressure (Front) BK E03 Mechanical system
2G43ZG Decrease of accumulator oil pressure (Rear) BK E03 Mechanical system
(989A00) Engine over run prevention activated MON E02 –
A570NX Engine oil filter clogging TM E01 Mechanical system
AA10NX Clogged air cleaner MON E01 Mechanical system
AB00MA Failure of battery charge circuit TM E03 Electrical system
B@BAZG Engine oil pressure is too low. ENG E03 Mechanical system
B@BAZK Engine oil level is too low. TM E01 Mechanical system
B@BCNS Engine overheat ENG E02 Mechanical system
B@BCZK Coolant level is too low. MON E01 Mechanical system
B@C6NS Overheat of brake cooling oil temperature (Front) MON E02 Mechanical system
18 HM400-2

Failure contents
B@C7NS Overheat of brake cooling oil temperature (Rear) MON E02 Mechanical system
B@C8NS Overheat of brake cooling oil temperature (Center) MON E02 Mechanical system
B@CENS Overheat of T/C fluid temperature MON E02 Mechanical system
B@JANS Overheat of steering oil temperature TM E02 Mechanical system
CA111 Abnormality in engine controller ENG E03 Electrical system
CA115 Abnormal engine Ne and Bkup speed sensors ENG E03 Electrical system
CA122 Charge pressure sensor too high ENG E03 Electrical system
CA123 Charge pressure sensor too low ENG E03 Electrical system
CA131 Throttle sensor tool high ENG E03 Electrical system
CA132 Throttle sensor too low ENG E03 Electrical system
CA135 Engine oil pressure sensor too high ENG E01 Electrical system
CA141 Engine oil pressure sensor too low ENG E01 Electrical system
CA144 Coolant temperature sensor too high ENG E01 Electrical system
CA145 Coolant temperature sensor too low ENG E01 Electrical system
CA153 Charge temperature sensor too high ENG E01 Electrical system
CA154 Charge temperature sensor too low ENG E01 Electrical system
CA187 Sensor power source 2 too low ENG E03 Electrical system
CA221 Atmospheric pressure sensor too high ENG E01 Electrical system
CA222 Atmospheric pressure sensor too low ENG E01 Electrical system
CA227 Sensor power source 2 too high ENG E03 Electrical system
CA234 Engine overspeed ENG E02 Mechanical system
CA238 Abnormal power source for Ne speed sensor ENG E03 Electrical system
CA263 Fuel temperature sensor too high ENG E01 Electrical system
CA265 Fuel temperature sensor too low ENG E01 Electrical system
CA271 PCV1 short circuit ENG E03 Electrical system
CA272 PCV1 disconnection ENG E03 Electrical system
CA273 PCV2 short circuit ENG E03 Electrical system
CA274 PCV2 disconnection ENG E03 Electrical system
CA322 Disconnection or short circuit in injector No.1(L No.1) ENG E03 Electrical system
CA323 Disconnection or short circuit in injector No.5 (L No.5) ENG E03 Electrical system
CA342 Abnormal engine controller data consistency ENG E03 Electrical system
CA351 Abnormal injector drive circuit ENG E03 Electrical system
CA352 Sensor power source 1 too low ENG E03 Electrical system
CA386 Sensor power source 1 too high ENG E03 Electrical system
CA431 Abnormal idle validation switch ENG E01 Electrical system
CA432 Abnormal process with idle validation ENG E03 Electrical system
CA441 Power source voltage too low ENG E03 Electrical system
CA442 Power source voltage too high ENG E03 Electrical system
CA449 Common rail pressure too high 2 ENG E03 Electrical system
CA451 Common rail pressure sensor too high ENG E03 Electrical system
HM400-2 19

Failure contents
CA452 Common rail pressure sensor too low ENG E03 Electrical system
CA553 Common rail pressure too high 1 ENG E03 Electrical system
CA554 Common rail pressure sensor: in range error ENG E03 Electrical system
CA559 Loss of pressure feed from supply pump 1 ENG E03 Electrical system
CA689 Abnormal engine Ne speed sensor ENG E03 Electrical system
CA731 Abnormal engine Bkup speed sensor phase ENG E03 Electrical system
CA757 Loss of all engine controller data ENG E03 Electrical system
CA778 Abnormal engine Bkup speed sensor ENG E03 Electrical system
CA1228 Abnormal EGR valve servo 1 ENG E03 Electrical system
CA1625 Abnormal EGR valve servo 2 ENG E03 Electrical system
CA1626 Short circuit of bypass valve solenoid drive ENG E03 Electrical system
CA1627 Disconnection in bypass valve solenoid drive ENG E03 Electrical system
CA1628 Abnormal bypass valve servo 1 ENG E03 Electrical system
CA1629 Abnormal bypass valve servo 2 ENG E03 Electrical system
CA1631 Bypass valve lift sensor too high ENG E03 Electrical system
CA1632 Bypass valve lift sensor too low ENG E03 Electrical system
CA1633 Abnormal KOMNET ENG E03 Electrical system
CA1642 EGR inlet pressure sensor too low ENG E01 Electrical system
CA1653 EGR inlet pressure sensor too high ENG E01 Electrical system
CA2185 Throttle sensor power source too high ENG E03 Electrical system
CA2186 Throttle sensor power source too low ENG E03 Electrical system
CA2249 Loss of pressure feed from supply pump 2 ENG E03 Electrical system
CA2271 EGR valve lift sensor too high ENG E03 Electrical system
CA2272 EGR valve lift sensor too low ENG E03 Electrical system
CA2351 EGR valve solenoid drive short circuit ENG E03 Electrical system
CA2352 EGR valve solenoid drive disconnection ENG E03 Electrical system
CA2555 Disconnection in intake air heater relay ENG E01 Electrical system
CA2556 Short circuit in intake air heater relay ENG E01 Electrical system
DAF9KM Wrong connection of connector MON E03 Electrical system
DAFRKR Abnormal CAN communication (machine monitor) TM E03 Electrical system
DAQ0KK Power source voltage too low TM E03 Electrical system
DAQ0KT Abnormal non volatile memory TM E01 Electrical system
DAQ2KK Solenoid power supply system failure TM E03 Electrical system
(DAQ9KQ) Inconsistent model selection (T/M controller) MON E03 –
DAQRKR Abnormal CAN communication (T/M controller) MON E03 Electrical system
(DAQRMA) Inconsistent option setting (T/M controller) MON E03 –
DB10KT Abnormal non volatile memory BK E03 Electrical system
DB12KK Solenoid power supply system failure BK E03 Electrical system
DB13KK Battery direct power supply too low BK E03 Electrical system
(DB19KQ) Inconsistent model selection (T/M controller) MON E03 –
(DB1QMA) Inconsistent option setting (T/M controller) MON E03 –
DB1RKR Abnormal CAN communication (T/M controller) TM E03 Electrical system
DB2RKR Abnormal CAN communication (engine controller) TM E03 Electrical system
DD1ML4 Inconsistent signal of axle connected retarder switch TM E01 Electrical system
20 HM400-2

Failure contents
DDTHKA Failure of flow detection valve for Hi clutch TM E03 Electrical system
DDTJKA Failure of flow detection valve for Lo clutch TM E03 Electrical system
DDTKKA Failure of flow detection valve for 1st clutch TM E03 Electrical system
DDTLKA Failure of flow detection valve for 2nd clutch TM E03 Electrical system
DDTMKA Failure of flow detection valve for 3rd clutch TM E03 Electrical system
DDTNKA Failure of flow detection valve for R clutch TM E03 Electrical system
DF10KA No lever signal input TM E03 Electrical system
DF10KB Multiple lever signal input TM E03 Electrical system
DGF1KX T/M oil temperature out of range TM E03 Electrical system
DGR2KZ Ground fault of brake oil temperature sensor (rear) system MON E01 Electrical system
DGR2L8 Disconnection of brake oil temperature sensor (rear) system MON E01 Electrical system
DGR3KZ Ground fault of brake oil temperature sensor (center) system MON E01 Electrical system
DGR3L8 Disconnection of brake oil temperature sensor (center) system MON E01 Electrical system
DGR4KZ Ground fault of brake oil temperature sensor (front) system MON E01 Electrical system
DGR4L8 Disconnection of brake oil temperature sensor (front) system MON E01 Electrical system
DGR6KX Steering oil temperature signal out of range TM E01 Electrical system
DGT1KX Short circuit of T/C oil temperature sensor system TM E01 Electrical system
Disconnection, ground fault, and short circuit of T/C fluid
DHT5KX TM E01 Electrical system
pressure sensor system
DHT5L6 T/C fluid pressure sensor failure TM E01 Electrical system
DHU2KX Accumulator fluid pressure sensor (front) system failure BK E01 Electrical system
DHU3KX Accumulator fluid pressure sensor (rear) system failure BK E01 Electrical system
DJF1KA Disconnection of fuel level sensor system MON E01 Electrical system
DK51L5 Manual retarder potentiometer and RVS failure BK E03 Electrical system
DK52KX Dump lever potentiometer failure 1 TM E03 Electrical system
DK53L8 Dump lever potentiometer failure 2 TM E03 Electrical system
DK54KX Body positioner sensor failure TM E03 Electrical system
DKH0KX Pitch angle sensor signal out of range TM E01 Electrical system
DLF1KA Disconnection of T/M input shaft speed sensor system TM E03 Electrical system
DLF1LC T/M input shaft speed sensor failure TM E03 Electrical system
DLF2KA Disconnection of T/M intermediate shaft speed sensor system TM E03 Electrical system
DLF2LC T/M intermediate shaft speed sensor failure TM E03 Electrical system
DLF4KA Disconnection of T/M differential speed sensor system TM E01 Electrical system
DLT3KA Disconnection of T/M output shaft speed sensor system TM E03 Electrical system
DV00KB Short circuit of buzzer output MON E01 Electrical system
Kick out solenoid output system failure (disconnection or ground
DW72KZ TM E01 Electrical system
fault)
DW73KZ Dump selector valve output system failure TM E03 Electrical system
DW78KZ Rear wheel BCV command output system failure BK E01 Electrical system
DW79KZ Front wheel BCV command output system failure BK E01 Electrical system
Rear wheels electromagnetic proportional pressure reducing
DX11K4 BK E03 Electrical system
valve failure 1
Disconnection of rear wheels electromagnetic proportional
DX11KA BK E03 Electrical system
pressure reducing valve output system
Ground fault of rear wheels electromagnetic proportional
DX11KB BK E03 Electrical system
pressure reducing valve output circuit
HM400-2 21

Failure contents
Hot short of rear wheels electromagnetic proportional pressure
DX11KY BK E03 Electrical system
reducing valve output circuit
Rear wheels electromagnetic proportional pressure reducing
DX11MA BK E03 Electrical system
valve failure 2
Front wheels electromagnetic proportional pressure reducing
DX12K4 BK E03 Electrical system
valve failure 1
Disconnection of rear wheels electromagnetic proportional
DX12KA BK E03 Electrical system
Ground fault of front wheels electromagnetic proportional
DX12KB BK E03 Electrical system
Hot short circuit of front wheels electromagnetic proportional
DX12KY BK E03 Electrical system
Front wheels electromagnetic proportional pressure reducing
DX12MA BK E03 Electrical system
valve failure 2
DX13KA Disconnection of Dump EPC valve output circuit TM E03 Electrical system
DX13KB Ground fault of Dump EPC valve output circuit TM E03 Electrical system
DX13KY Hot short circuit of Dump EPC valve output circuit TM E03 Electrical system
DX14KZ Rear wheels differential lock-up command output system failure BK E03 Electrical system
DX15KZ Front wheels differential lock-up command output system failure BK E03 Electrical system
Disconnection of inter axle differential lock-up clutch solenoid
DXH0KA TM E01 Electrical system
output circuit
Ground fault of inter axle differential lock-up clutch solenoid
DXH0KB TM E01 Electrical system
output circuit
Hot short circuit of inter axle differential lock-up clutch solenoid
DXH0KY TM E03 Electrical system
output circuit
DXH1KA Disconnection of L/U clutch solenoid output circuit TM E03 Electrical system
DXH1KB Ground fault of lock-up clutch solenoid output circuit TM E03 Electrical system
DXH1KY Hot short circuit of lock-up clutch solenoid output circuit TM E03 Electrical system
DXH2KA Disconnection of Hi clutch solenoid output circuit TM E03 Electrical system
DXH2KB Ground fault of Hi clutch solenoid output circuit TM E03 Electrical system
DXH2KY Hot short circuit of Hi clutch solenoid output circuit TM E03 Electrical system
DXH3KA Disconnection of Lo clutch solenoid output circuit TM E03 Electrical system
DXH3KB Ground fault of Lo clutch solenoid output circuit TM E03 Electrical system
DXH3KY Hot short circuit of Lo clutch solenoid output circuit TM E03 Electrical system
DXH4KA Disconnection of 1st clutch solenoid output circuit TM E03 Electrical system
DXH4KB Ground fault of 1st clutch solenoid output circuit TM E03 Electrical system
DXH4KY Hot short circuit of 1st clutch solenoid output circuit TM E03 Electrical system
DXH5KA Disconnection of 2nd clutch solenoid output circuit TM E03 Electrical system
DXH5KB Ground fault of 2nd clutch solenoid output circuit TM E03 Electrical system
DXH5KY Hot short circuit of 2nd clutch solenoid output circuit TM E03 Electrical system
DXH6KA Disconnection of 3rd clutch solenoid output circuit TM E03 Electrical system
DXH6KB Ground fault of 3rd clutch solenoid output circuit TM E03 Electrical system
DXH6KY Hot short circuit of 3rd clutch solenoid output circuit TM E03 Electrical system
DXH7KA Disconnection of R clutch solenoid output circuit TM E03 Electrical system
DXH7KB Ground fault of R clutch solenoid output circuit TM E03 Electrical system
DXH7KY Hot short circuit of R clutch solenoid output circuit TM E03 Electrical system
22 HM400-2
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
BK : Retarder controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
HM400-2 23
t Service mode
Procedure for switching to service mode and
screen display
a When using the service mode, change the
screen by the following special operation.
1. Confirming the screen display

Check that the machine monitor is in operator
mode and the screen is displaying either of the
"service meter and integrated odometer",
"action code", or "failure code".
2. Displaying ID input initial screen

Press the following 2 switches at the same
time for longer than 5 seconds to display the ID 4. Displaying service menu selection screen
input screen. After confirming all 4 digits of ID, display the
q [t] switch and [<] switch service menu selection screen in the service
a If the switch is pressed for longer than 5 mode.
seconds, the character display section a By inputting and determining the ID once,
becomes blank. After confirming this con- it will be effective until the starting switch
dition, release the switch. is turned off.
3. Input and determination of ID 5. Selection of the service menu

After displaying ID input screen, operate [>], If the [>] switch or [<] switch is pressed on the
[<], [U], and [t] switch and input 4 digits ID. service menu selection screen, the service
a ID: 6491 menu is displayed endlessly in the order of the
q [ > ]:Number at the cursor increases. following table, then select the menu that is
q [ < ]:Number at the cursor decreases used.
q [U]: Number at the cursor is determined q [>]: To proceed to next service menu.
q [t ]: Cursor moves to left end or the dis- q [<]: To return to previous service menu.
play returns to operator mode screen.
a If the ID input screen is left without switch
operation for longer than 60 seconds, it
automatically returns to the operator mode
screen.
24 HM400-2
a Displayed service menu: [9] Electrical system failure history display

function (ELECTRIC FAULT)
No. Display Function
The machine monitor retains the data for problems
Electrical system failure history that occurred in the electrical system in the past as
1 ELECTRIC FAULT
display function failure history. They can be displayed as follows.
Mechanical system failure 1. Selection of the service menu
2 MACHINE FAULT
history display function Select electrical system failure history display
REAL-TIME function (ELECTRIC FAULT) in the service
3 Real-time monitoring function menu selection screen.
MONITOR
CYLINDER a The total number of failure history data
4 Reduced cylinder mode items recorded in memory is displayed in
CUT-OUT
the [* *] portion.
5 NO INJECTION No injection cranking function
6 TUNING Adjusting function
MAINTENANCE Filter and oil replacement time
7
MONITOR setting function
Operation information display
8 OPERATION INFO
function
OPTIONAL
9 Option selection function
SELECTION
10 MACHINE Model selection function
Initialize function (exclusive
11 INITIALIZE
function for factory)
a The service menu is displayed in the

places marked with [*].
2. Failure history data display
With the service menu selected, press the [U]
switch and display the failure history data
recorded in memory.
6. Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current function and hierarchy.
q When continuing operations in another
mode or function: 3. Displayed failure history data
Press the [t] switch and return to the With the electrical system failure history dis-
mode screen to be used or menu screen play function, the following data can be dis-
to be used. played.
a Note that if the [t] switch is pressed 1: Record number (recorded up to a maxi-
on the YES/NO screen, the function mum of 20 items)
will be executed. A: Failure code (4-digits device code + 2-dig-
a If you return to the operator mode its symptom code)
screen by mistake, repeat the proce- 2: Number of occurrences (number of occur-
dure from step 1 above (however rences of same code in the past)
there is no need to input the ID again). 3: Elapsed time 1 (time elapsed on service
q When completing all operations: meter since first occurrence)
Turn the starting switch OFF.
HM400-2 25
4: Elapsed time 2 (time elapsed on service

meter since last occurrence)
a Failure codes for problems that are still
existing are shown on a flashing display.
a Refer to failure code table of operator
mode for details of displayed failure
codes.
a Note that with the failure history display
function and failure code display function
(operator mode) for the electrical system,
the displayed data are partially different.
a If the fault history is not recorded, "-" is
displayed on the display section of 1/A/2/
3/4.
6. Deletion of all the failure history information
1) With the failure history data displayed,
press the [>] switch or [<] switch and dis-
play ALL CLEAR menu screen.
a The ALL CLEAR menu is displayed at
the end of failure history data.
4. Switching failure history display

If the [>] switch or [<] switch is pressed during
the display of failure history, the display
switches to another failur e history data
recorded.
q [>]: To proceed to data for next record 2) When the ALL CLEAR menu is displayed,
number press the [U] switch and display the ALL
q [<]: Go back to data for previous record CLEAR execution screen.
number q [U]: Execute ALL CLEAR menu
3) When the ALL CLEAR execution screen is
5. Deleting individual failure history data displayed, operate each switch of [<], [>]
1) With the failure history data to be deleted and [t].
displayed, press the [U] switch and dis- q [ <]: Select YES (move cursor)
play the individual deletion screen. q [ >]: Select NO (move cursor)
q [U]: Display the deletion screen q [t]: Execute YES or NO
2) When the individual deletion screen is dis- a An information which is active cur-
played, operate each switch of [<], [>] and rently (display is flashing) cannot be
[t]. deleted.
q [ < ]: Select YES (move cursor)
q [ > ]: Select NO (move cursor)
q [t]: Execute YES or NO
a An information which is active cur-
rently (display is flashing) cannot be
deleted.
26 HM400-2
[10] Mechanical system failure history display 4: Elapsed time 2 (time elapsed on service
function (MACHINE FAULT) meter since last occurrence)
The machine monitor retains the data for problems a Failure codes for problems that are still
that occurred in the mechanical system in the past existing are shown on a flashing display.
as failure history. They can be displayed as fol- a Refer to failure code table of operator
lows. mode for details of displayed failure
codes.
1. Selection of the service menu a Note that with the failure history display
Select mechanical system failure history dis- function and failure code display function
play function (MACHINE FAULT) in the service (operator mode) for the mechanical sys-
menu selection screen. tem, the displayed data are partially differ-
a The total number of failure history data ent.
items recorded in memory is displayed in a If the fault history is not recorded, "-" is
the [* *] portion. displayed on the display section of 1/A/2/
3/4.
2. Failure history data display

With the service menu selected, press the [U] 4. Switching failure history display
switch and display the failure history data If the [>] switch or [<] switch is pressed during
recorded in memory. the display of failure history, the display
q [U]: Conduct the service menu. switches to another failure histor y data
recorded.
q [>]: To proceed to data for next record
number
q [<]: Go back to data for previous record
number
5. Deleting failure history data (not permitted)

a The failure history data for the mechanical
system cannot be deleted.
3. Displayed failure history data

With the mechanical system failure history dis-
play function, the following data can be dis-
played.
1: Record number
A: Failure code (4-digits device code + 2-dig-
its symptom code)
2: Number of occurrences (number of occur-
rences of same code in the past)
3: Elapsed time 1 (time elapsed on service
meter since first occurrence)
HM400-2 27
[11] Real time monitoring function (REAL-TIME a Monitoring system and function to be
MONITOR) displayed:
The machine monitor can monitor the condition of
No. Display System and function
the machine in real time through the signals from
the sensors installed to various parts of the 1 MONITOR PANEL Machine monitor system
machine. 2 TRANSMISSION Transmission controller system
In the real time monitoring function, the following 2 3 ENGINE Engine controller system
types of display can be shown.
4 BRAKE Retarder controller system
q 1 item independent display (for each controller)
q 2 items simultaneous display (code input) 2 items simultaneous monitor-
5 2 ITEMS
ing
1. Selection of the service menu a Display monitoring system and func-
Select real time monitoring function (REAL- tion in the "*" section.
TIME MONITOR) in the service menu selec-
tion screen.
3. Setting 1 item individual monitoring

1) In the monitoring system and function
2. Display and selection of monitoring system selection screen, select the monitoring
and function system (example: ENGINE) to be used.
1) With the service menu selected, press the
[U] switch to display the monitoring sys-
tem and function selection screen.
2) With the monitoring system selected,

press the [U] switch and display the mon-
itoring display and item selection screen.
q [U]: Implement 1 system individual
2) If the [>] switch or [<] switch is pressed on monitoring
the monitoring system and function selec- 3) With the monitoring display and item
tion screen, the monitoring system and selection screen displayed, press the [>]
device is displayed endlessly in the follow- switch or [<] switch and select items to
ing order, then select the system or func- monitor.
tion that is used. q [>]: To proceed to the next monitoring
q [>]: To proceed to next monitoring item
system and function q [<]: Return to the previous monitoring
q [<]: Go back to data for previous item
monitoring system and function
28 HM400-2
a The monitored items are scroll-dis- q [U]: Implement 2 system individual

played due to internal setting. monitoring
a If the switch is kept pressed, the mon-
itoring items scroll at high speed.
a In the monitoring display and item
selection screen, the information of
the monitored items are displayed on
real time.
3) In the monitoring code input screen, oper-

ate each of the switches [>], [<], [U] and
[t], and directly input 2-digit monitoring
codes.
q [ < ]: Number at the cursor decreases
4) To hold or cancel monitoring data: q [U]: Number at the cursor is deter-
If the [U] switch is pressed during moni- mined
toring, the monitor data is held and the q [t ]: Cursor moves to the left end / To
[U] mark flashes. If the [U] switch is return to the monitoring system
pressed again, hold is canceled and it and function selection screen.
becomes active again.
q [U]: Hold and release of data
4. Display data for 1 item individual monitoring

On the 1 item individual monitoring display
screen, the following data are displayed.
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
a For details, see "Monitoring code table".
4) When both of the monitoring codes have

been confirmed, the screen switches to
the 2 items simultaneous monitoring dis-
play screen.
5. Setting 2 items simultaneous monitoring

1) Select 2 items simultaneous monitoring (2
ITEMS) in the monitoring system and
function selection screen.
2) With 2 items simultaneous monitoring
selected, press the [U] switch and display
the monitoring code input screen.
HM400-2 29
5) To hold or cancel monitoring data:

If the [U] switch is pressed during moni-
toring, the monitor data is held and the
[U] mark flashes.
If the [U] switch is pressed again, hold is
canceled and it becomes active again.
q [U]: Hold and release of data
6. Display data for 2 items simultaneous monitor-

ing
On the 2 item simultaneous monitoring display
screen, the following data are displayed.
A : Monitoring code 1
1 : Monitoring data 1 (including unit)
B : Monitoring code 2
2 : Monitoring data 2 (including unit)
a For details, see "Monitoring code table".
30 HM400-2
Monitoring code table

MONITOR PANEL [Machine monitor system]
Monitoring
No. Monitoring items Item display Data display range Unit
code
********
1 Software product number VERSION 20200 —
(Number, symbols with 8 digits)
********
2 Application version VERSION (APP) 20221 —
VERSION ********
3 Data version 20222 —
(DATA) (Number, symbols with 8 digits)
4 Engine speed ENG SPEED 01001 0 – 65535 rpm
km/h or MPH
5 Travel speed SPEED 40000 (Travel speed is displayed)
(per setting)
6 Resistance of fuel level sensor FUEL SENSOR 04202 0 – 150 z
7 Voltage of fuel level sensor FUEL SENSOR 04207 0.00 – 5.00 V
8 Brake oil temperature (front) BRAKE OIL T F 30201 0 – 160 °C
Brake oil temperature sensor
9 BRAKE OIL T F 30204 0.00 – 5.00 V
voltage (front)
10 Brake oil temperature (center) BRAKE OIL T M 30203 0 – 160 °C
11 BRAKE OIL T M 30206 0.00 – 5.00 V
voltage (center)
12 Brake oil temperature (rear) BRAKE OIL T R 30202 0 – 160 °C
13 BRAKE OIL T R 30205 0.00 – 5.00 V
voltage (rear)
14 Rheostat (nighttime dimmer) RHEOSTAT 30300 0.0 – 51.0 V
15 Rotary switch (SW1 – 3) SW1, SW2, SW3 30202 0 – F, 0 – F, 0 – F Status display
16 Dip switch (SW5-1, 2) SW5-1, SW5-2 30205 ON/OFF, ON/OFF Status display
01010101
20 Input signal (0 – 7) D-IN--0-------7 40900 0: OFF/ 1: ON
(0/1 8 digits, see detail)
01010101
21 Input signal (8 – 15) D-IN--8------15 40901 0: OFF/ 1: ON
01010101
01010101
01010101
0101
25 Output signal (0 – 3) D-OUT-0--3 40925 0: OFF/ 1: ON
HM400-2 31
Detailed information of 40900 (D-IN--0------7) [39]:(Spare)

[0]:Dimmer switch (High beam: 1)
[1]:Accelerator connected retarder switch (Upper Detailed information of 40925 (D-OUT-0--3)
side: 1) [0]:Buzzer (Operating: 1)
[2]:AISS LOW switch (LOW: 1) [1]:(Not in use)
[3]:(Not in use) [2]:(Not in use)
[4]:Inter axle differential lock switch (MANUAL: 1) [3]:(Not in use)
[5]:Dimmer switch (Passing: 1)
[6]:(Not in use)
[7]:Power mode switch (Economy mode: 1)
Detailed information of 40901 (D-IN--8------15)

[8]:Connector check (Constant 1)
[9]:Machine monitor mode selector switch 1
(Pushing [t]: 1)
(Pushing [>]: 1)
[11]: Machine monitor mode selector switch 2
(Pushing [<]: 1)
[12]:Turn signal lever (Operate right: 1)
[13]:Turn signal lever (Operate left: 1)
(Pushing [U]: 1)
[15]:(Not in use)

[16]:(Not in use)
[17]:Retarder cooling oil filter (Equipping: 1)
[18]:Air cleaner (***: 1)
[19]:Hydraulic oil filter sensor (Equipping: 1)
[20]:Hydraulic oil level sensor (Equipping: 1)
[21]:(Not in use)
[22]:Coolant level sensor (***: 1)
[23]:(Not in use)

[24]:Lamp switch (Night illumination ON: 1)
[25]:Seatbelt switch (ON: 1)
[26]:Left and right differential lock pedal
(Pressed: 1)
[27]:(Not in use)
[28]:Left and right differential lock switch 1
(In upper position: 1)
[29]:(Not in use)
[30]:Left and right differential lock switch 2
(In lower position: 1)
[31]: Accelerator connected retarder switch (ON: 1)

[32]:(Not in use)
[33]:(Not in use)
[34]:Connector check (Constant 1)
[35]:(Not in use)
[36]:Service switch (ON: 1)
(Pushing [>]: 1)
(Pushing [<]: 1)
32 HM400-2
TRANSMISSION [Transmission controller system]

Monitoring
code
********
1 Software product number VERSION 20201 —
********
********
3 Data version VERSION (DATA) 20224 —
Transmission input shaft
4 T/M SPEED: IN 31200 0 – 32767 rpm
speed
Transmission intermediate
5 T/M SPEED: MID 31300 0 – 32767 rpm
shaft speed
Transmission output shaft
6 T/M SPEED:OUT 31400 0 – 32767 rpm
speed
Transmission differential
7 T/M DIFF OUT 31402 0 – 65535 rpm
speed
0
8 Alternator R signal ALTERNATOR R 04301 0: OFF/ 1: ON
(0/1 1 digit)
Torque converter oil
9 T/C OIL TEMP 30100 0 – 160 °C
temperature
Voltage of torque converter oil
10 T/C OIL TEMP 30101 0.00 – 5.00 V
temperature sensor
11 Transmission oil temperature T/M OIL TEMP 32500 0 – 160 °C
Voltage of transmission oil
12 T/M OIL TEMP 32501 0.00 – 5.00 V
temperature sensor
13 Steering oil temperature STRG OIL TEMP 32701 0 – 160 °C
Voltage of steering oil
14 STRG OIL TEMP 32702 0.00 – 5.00 V
temperature sensor
15 Torque converter oil pressure T/C OIL PRESS 32600 0.00 – 5.00 MPa
Voltage of torque converter oil
16 T/C OIL PRESS 32605 0.00 – 5.00 V
pressure sensor
01010
17 Clutch fill switch FILL HLR123 38921 0: OFF/ 1: ON
(0/1 5 digits)
18 Solenoid output current (Hi) ECMV H DIR 31600 0 – 1000 mA
19 Solenoid output current (Lo) ECMV L DIR 31601 0 – 1000 mA
20 Solenoid output current (1st) ECMV 1 DIR 31602 0 – 1000 mA
21 Solenoid output current (2nd) ECMV 2 DIR 31603 0 – 1000 mA
22 Solenoid output current (3rd) ECMV 3 DIR 31604 0 – 1000 mA
23 Solenoid output current (R) ECMV R DIR 31606 0 – 1000 mA
24 Solenoid output current (L/U) ECMV LU DIR 31609 0 – 1000 mA
25 Solenoid output current (DIFF) ECMV D DIR 31607 0 – 1020 mA
26 Angle of inclination ANGLE SENSOR 32900 -180.0 – +180.0 °
27 Pitch angle sensor voltage ANGLE SENSOR 32902 0.00 – 5.00 V
28 Brake output (front wheel) BK OUTP DIR F 44900 0 – 100 %
29 Brake output (rear wheel) BK OUTP DIR R 44901 0 – 100 %
30 Throttle correction value THROTTLE MOD 36000 -100 – 100 %
31 Body positioner sensor voltage BODY POSITION 34603 0.00 – 5.00 V
Dump lever potentiometer 1
32 DUMP LEVER 1 34506 0.00 – 5.00 V
voltage
HM400-2 33

Monitoring
code
Dump lever potentiometer 2
33 DUMP LEVER 2 34507 0.00 – 5.00 V
voltage
0
34 Body seating sensor BODY SEATING 34600 0: OFF/ 1: ON
(0/1 1 digit)
Seating control command
35 S CNT DIR H 45100 0 – 1000 mA
current ( /Hi)
Seating control command
36 S CNT DIR L 45101 0 – 1000 mA
current ( /Lo)
37 Seating calibration value ( ) S CAL A 45200 0.00 – 5.00 V
Cylinder stopper calibration
38 S CAL B 45300 0.00 – 5.00 V
value ( )
39 Seating control time (Hi) S CNT TIME H 45400 0.0 – 10.00 s
40 Dump EPC output current HOIST EPC DIR 45601 0 – 1000 mA
41 Seating control time (Lo) S CNT TIME L 45401 0.0 – 10.00 s
Lo clutch trigger compensation 00000000 – FFFFFFFF
42 TRIGGER MOD L 38900 Status display
amount (0 – F 8 digits)
Hi clutch trigger compensation 00000000 – FFFFFFFF
43 TRIGGER MOD H 38901 Status display
1st clutch trigger 00000000 – FFFFFFFF
44 TRIGGER MOD 1 38902 Status display
compensation amount (0 – F 8 digits)
2nd clutch trigger 00000000 – FFFFFFFF
3rd clutch trigger 00000000 – FFFFFFFF
R clutch trigger compensation 00000000 – FFFFFFFF
47 TRIGGER MOD R 38906 Status display
01010
48 Trigger initial learning flag TRIG HLR123 38922 0: OFF/ 1: ON
(0/1 5 digits)
49 Clutch fill time (Lo) FILL TIME L 41800 0 – 2550 ms
50 Clutch fill time (Hi) FILL TIME H 41801 0 – 2550 ms
51 Clutch fill time (1st) FILL TIME 1 41802 0 – 2550 ms
52 Clutch fill time (2nd) FILL TIME 2 41803 0 – 2550 ms
53 Clutch fill time (3rd) FILL TIME 3 41804 0 – 2550 ms
54 Clutch fill time (R) FILL TIME R 41806 0 – 2550 ms
Throttle amount lower limit
55 THROT LIMIT LO 44201 0.0 – 100.0 %
output
Throttle amount upper limit
56 THROT LIMIT HI 44200 0.0 – 100.0 %
output
01010101
57 Input signal (0 – 7) D-IN--0-------7 40905 0: OFF/ 1: ON
01010101
01010101
01010101
0
(0/1 1 digit, see detail)
01010101
62 Output signal (0 – 7) D-OUT--0-------7 40949 0: OFF/ 1: ON
34 HM400-2

Monitoring
code
01010101
63 Output signal (8 – 15) D-OUT--8------15 40950 0: OFF/ 1: ON
01010101
64 Output signal (16 – 23) D-OUT--16------23 40951 0: OFF/ 1: ON
Detailed information of 40905 (D-IN--0------7) Detailed information of 40949 (D-OUT-0------7)

[1]:(Not in use) [1]:Dump switch solenoid (ON: 1)
[2]:Emergency steering relay 2 (Driving: 1) [2]:(Not in use)
[4]:Starting switch C terminal signal [4]:(Not in use)
(Starting engine: 1) [5]:Dump lever kick-out solenoid (Operating: 1)
[5]:Emergency steering relay 1 (Driving: 1) [6]:(Not in use)
[6]:Shift hold switch (ON: 1) [7]:(Not in use)
[7]:Shift lever (N position: 1)
Detailed information of 40950 (D-OUT-8-----15)
Detailed information of 40906 (D-IN--8------15) [8]:(Not in use)
[9]:Lo clutch fill switch (ON: 1) [10]:(Not in use)
[10]:Hi clutch fill switch (ON: 1) [11]: (Not in use)
[11]: 1st clutch fill switch (ON: 1) [12]:(Not in use)
[12]:2nd clutch fill switch (ON: 1) [13]:(Not in use)
[13]:3rd clutch fill switch (ON: 1) [14]:(Not in use)
[14]:R clutch fill switch (ON: 1) [15]:(Not in use)
[15]:(Not in use)
Detailed information of 40951 (D-OUT-16----23)
[16]:Shift lever (R2 position: 1) [17]:(Not in use)
[17]:Shift lever (R1 position: 1) [18]:(Not in use)
[18]:Shift lever (D position: 1) [19]:(Not in use)
[19]:Shift lever (5 position: 1) [20]:(Not in use)
[23]:Shift lever (1 position: 1)

[24]:T/M oil filter clogging switch (ON: 1)
[25]:(Not in use)
[26]:(Not in use)
[27]:Emergency escape switch (ON: 1)
[28]:Engine oil level switch (ON: 1)
[29]:Engine oil filter clogging switch (ON: 1)
[30]:(Not in use)
[31]:(Not in use)

[32]:(Not in use)
HM400-2 35
ENGINE [Engine controller system]

Monitoring
code
1 Hardware S/N ECM S/N 20400 0 – 49999999 —
2 Battery voltage POWER SUPPLY 03200 0.0 – 480.0 V
3 Engine speed ENG SPEED 01002 0 – 4000 rpm
4 Coolant temperature COOLANT TEMP 04104 -40 – 210 °C
Voltage of coolant
5 COOLANT TEMP 04105 0.00 – 5.00 V
temperature sensor
6 Oil pressure sensor ENG OIL PRESS 37200 -99.9 – 999.9 kPa
7 Oil pressure sensor voltage ENG OIL PRESS 37201 0.00 – 5.00 V
8 Common rail pressure RAIL PRESS 36400 0 – 400 MPa
Common rail pressure sensor
9 RAIL PRESS 36401 0.00 – 5.00 V
voltage
10 Atmospheric pressure AMBIENT PRESS 37400 -99.9 – 999.9 kPa
Atmospheric pressure sensor
11 AMBIENT PRESS 37401 0.00 – 5.00 V
voltage
12 Fuel temperature FUEL TEMP 04204 -40 – 210 °C
Fuel temperature sensor
13 FUEL TEMP 04205 0.00 – 5.00 V
voltage
14 Boost temperature CHG TEMP 18500 -50 – 200 °C
Boost temperature sensor
15 CHG TEMP 18501 0.00 – 5.00 V
voltage
16 Boost pressure CHG PRESS-A 36500 -99.9 – 999.9 kPa
17 Boost pressure sensor voltage CHG PRESS-A 36501 0.00 – 5.00 V
18 EGR valve inlet pressure EGR IN PRESS-A 18000 -99.9 – 999.9 kPa
EGR valve inlet pressure
19 EGR IN PRESS-A 18001 0.00 – 5.00 V
sensor voltage
20 EGR valve position EGR VALVE POS 18100 0.00 – 99.99 mm
EGR valve position sensor
21 EGR VALVE POS 18101 0.00 – 5.00 V
voltage
22 Engine output torque OUTPUT TORQUE 18700 -24000 – 24000 Nm
23 Converted torque TORQUE RATIO 36700 0 – 100 %
Final accelerator opening
24 FINAL THROTTLE 31706 0 – 100 %
angle
Instantaneous fuel
25 FUEL RATE 37300 0.0 – 999.9 L/h
consumption
Command for final injection
26 INJECT COMMAND 18600 0 – 1000 mg
amount (unit of weight)
Final injection timing
27 INJECT TIMING 36300 -180.0 – 180.0 CA
command (TFIN)
Accelerator pedal opening
28 THROTTLE POS 31701 0 – 100 %
angle
Accelerator pedal sensor
29 THROTTLE POS 31702 0.00 – 5.00 V
voltage
30 Bypass valve position BPS VALVE POS 18200 0.00 – 99.99 mm
Bypass valve position sensor
31 BPS VALVE POS 18201 0.00 – 5.00 V
voltage
32 Idle validation signal 1 IVS 1 18300 ON/OFF Status display
33 Idle validation signal 2 IVS 2 18301 ON/OFF Status display
36 HM400-2
ENGINE [Engine controller system]

Monitoring
code
34 Controller inside temperature ECM IN TEMP 18900 -40 – 210 °C
Final common rail pressure
35 PRESS COMMAND 36200 0 – 400 MPa
command (PFIN)
PCV valve closing timing
36 PCV TIMING 17201 -180.0 – 180.0 CA
(from BTDC)
0
37 Engine mode selection POWER MODE 17500 Status display
(0 - 4 1 digit)
Selected model name ********
38 MACHINE ID (H) 00400 —
(upper 8 digits) (Number, symbols with 8 digits)
Selected model name ********
39 MACHINE ID (L) 00401 —
(lower 8 digits) (Number, symbols with 8 digits)
********
40 Build version BUILD VER UNIT 20216 —
********
41 Calibration Data version CAL VER 20217 —
a Unit "CA" means the crankshaft angle.
HM400-2 37
BRAKE [Retarder controller system]

Monitoring
code
********
1 Software version VERSION 20214 —
********
VERSION ********
3 Data version 20232 —
(DATA) (Number, symbols with 8 digits)
0
4 Alternator R signal ALTERNATOR R 04302 0: OFF/ 1: ON
(0/1 1 digit)
Accumulator oil pressure
5 ACC OIL PRE F 35500 0.00 — 99.99 MPa
(front)
6 ACC OIL PRE F 05506 0.00 – 5.00 V
sensor signal (front)
7 ACC OIL PRE R 35501 0.00 — 99.99 MPa
(rear)
8 ACC OIL PRE R 25507 0.00 – 5.00 V
sensor signal (rear)
Brake output current
9 BK OUTP DIR F 33807 0 – 1000 mA
(front wheel)
Brake output current
10 BK OUTP DIR R 33806 0 – 1000 mA
(rear wheel)
11 Retarder lever voltage RETARD LEVER 33900 0.00 – 5.00 V
01010101
12 Input signal (0 – 7) D-IN--0-------7 40932 Status display
01010101
13 Input signal (8 – 15) D-IN--8------15 40933 Status display
01010101
01010101
0
(0/1 1 digit, see detail)
01010101
17 Output signal (0 – 7) D-IN--0-------7 40955 Status display
01010101
18 Output signal (8 – 15) D-IN--8------15 40956 Status display
01010101
19 Output signal (16 – 23) D-IN--16------23 40957 Status display
38 HM400-2
Detailed information of 40932 (D-IN--0------7) Detailed information of 40955 (D-OUT-0-----7)

[0]:(Not in use) [0]:Left and right differential output (front)(when
[1]:Brake pedal switch (ON: 1) operating: 1)
[2]:Front retarder switch (ON: 1) [1]:Left and right differential output (rear)(when
[3]:Rear retarder switch (ON: 1) operating: 1)
[4]:Idle validation switch 1 (ON: 1) [2]:BVC output (front)(when operating: 1)
[5]:Idle validation switch 2 (ON: 1) [3]:BVC output (rear) (when operating: 1)
[6]:(Not in use)
[8]:Front differential oil pressure switch (ON: 1)
[9]:Rear differential oil pressure switch (ON: 1) Detailed information of 40956 (D-OUT-8-----15)
[11]: (Not in use) [9]:(Not in use)
[12]:Parking brake switch (ON: 1) [10]:(Not in use)
[13]:(Not in use) [11]: (Not in use)
[14]:(Not in use)
[16]:Starting switch C terminal signal (when engine
start: 1) Detailed information of 40957 (D-OUT-16----23)
[23]:(Not in use)
[24]:(Not in use)
[25]:(Not in use)
[26]:(Not in use)
[27]:(Not in use)
[28]:(Not in use)
[29]:(Not in use)
[30]:(Not in use)
[31]:(Not in use)

[32]:(Not in use)
HM400-2 39
[12] Reduced cylinder mode (CYLINDER CUT- 3. Setting cut-out cylinder

OUT) In the reduced cylinder mode execution
As one method of troubleshooting for the engine, screen, operate each of the switches [>], [<],
the machine monitor has a reduced cylinder mode [U] and [t] to select the cut-out cylinder.
that can set the desired cylinder to the no injection q [ > ]: Selector cursor moves to the right.
condition. q [ < ]: Selector cursor moves to the left.
q [U]: Determine the cylinder.
1. Starting engine q [ t]: To return to the service menu selec-
Use this function while the engine is running, tion screen.
because a defective cylinder is determined a When the [U] switch is used to confirm
depending on the engine speed in the reduced the cut-out cylinder, communication is car-
cylinder mode. ried out between the machine monitor and
engine controller. During this time, the cyl-
2. Selection of the service menu inder No. flashes.
1) Select the reduced cylinder mode (CYLIN- After completion of the communication,
DER CUT-OUT) in the service menu the segment under the cylinder No.
selection screen. becomes black to show that the cylinder
has been cut out.
a A single cylinder or multiple cylinders can
be cut out.

[U] switch and display the reduced cylin-
der mode implementation screen.
4. Canceling cylinder cut-out
a The cylinder No. and the engine
Cancellation of cylinder cut-out is done by the
speed are displayed on the upper
same procedure as setting cut-out cylinder.
line, and the final injection amount
a When the [U] switch is used to confirm
command is displayed on the lower
the cancellation of the cut-out cylinder,
line.
communication is carried out between the
a When being switched to the reduced
machine monitor and engine controller.
cylinder mode implementation
During this time, the cylinder No. flashes.
screen, the cursor of cylinder selec-
After completion of the communication,
tion is always displayed under the
the segment under the cylinder No.
No.1 cylinder.
becomes white to show that the cylinder
cut-out has been canceled.
40 HM400-2
[13] No injection cranking function a None injection cranking function cannot

(NO INJECTION) be used during engine running.
The machine monitor has the function of none
injection cranking, which carries out cranking after
long-term storage, stopping fuel injection of all the
cylinders without starting the engine.
a The function of none injection cranking must
be operated under the condition that the
engine is stopped.
1. Selection of the service menu

In the service menu selection screen, select
none injection cranking function (NO INJEC-
TION).
4. Canceling no injection cranking

If the [t] switch is pressed on the no injection
cranking execution screen, the screen returns
to the service menu selection screen and the
no injection cranking is cancelled.
q [t]: To return to the service menu selec-
tion screen.
2. Establishment of no injection cranking

With the service menu selected, press the [U]
switch to display none injection cranking exe-
cution screen.
a If "CRANKING READY" is displayed on
the lower line, the none injection cranking
is set.
a If the starting switch is operated to the
START position under this condition, the
engine cranks but will not start.
3. Setting is denied during engine running

During engine running, if the setting of none
in jec tion c ran ki ng i s attem pted, "S TO P
ENGINE" is displayed in the lower line, and
setting is rejected.
HM400-2 41
[14] Adjustment function (TUNING) 1) Select real time monitoring function

Machine monitor can run "Adjusting transmission (REAL-TIME MONITOR) in the service
ECMV electric current" and "Reset the transmission menu selection screen.
initial learning and implement learning " through the
transmission controller.

The adjustment is implemented by operating the tem and function selection screen.
machine monitor and machine body following the q [U]: Runs service menu
below procedure. 3) In the monitoring system and function
1. Preparing operations for "Adjusting transmis- selection screen, press [>] switch or [<]
sion ECMV electric current" switch to select transmission system
(Real time monitoring function) (TRANSMISSION).
2. Adjusting transmission ECMV electric current q [>]: To proceed to next monitoring
(02: AUTO of ECMV TUNING) system and function
3. Reset the transmission initial learning and q [<]: To go back to data for previous
implement learning (TUNED/Real-time moni- monitoring system and function
toring function for 01: TM TRIGGER)
a ( ) indicates service menu or adjustment func-
tion used for the adjustment.
a [MANUAL] menu of [02: ECMV TUNING] is the
function only used by plants and not used by
services.
a For details concerning the operation method of
real time monitoring function, refer to "[11] real
time monitoring function".
4) With the transmission system selected,

press the [U] switch and display the mon-
itoring display and item selection screen.
q [U]: Implement 1 system individual
monitoring
q The program version No. is displayed
on ********.
5) In the monitoring display and item selec-
tion screen, press [>] switch or [<] switch
and select monitoring code of transmis-
1. Preparing operations for "Adjusting trans- sion oil temperature.
mission ECMV electric current" q [>]: Goes on to the next monitoring
a The adjusting operation should be carried item
out with the specified oil temperature. q [<]: Goes back to the previous moni-
Confirm the machine is not displaying toring item
abnormality and adjust the transmission oil q Monitoring code:
temperature following the next procedure. 32500 (T/M OIL TEMP)
42 HM400-2
q Parking break switch: ON

q AISS LOW switch: LOW (low speed)
q Gear shift lever: N position
q Engine: Low idling
q Accelerator pedal: OFF (Release)
3) Return to the service menu selection
screen, and select the adjustment function
(TUNING).
a Press [t] switch several times to
return to the service menu selection
screen.
6) Confirm that the parking brake switch is

ON, and start the engine.
7) Depress the brake pedal, and set the gear
shift lever to D position.
a Confirm that the shift indicator dis-
plays "F2".
8) Stall the torque converter and raise the
transmission oil temperature up to 60 – 70
°C.
a Be careful not to overheat the oil
while stalling the torque converter.
9) Return the gear shift lever to N position, 4) With the service menu selected, press the
keep it for 3 minutes, and confirm that the [U] switch to display the adjustment menu
transmission oil temperature is stable selection screen.
between 60 – 70 °C. a Hold down the [U] switch for a mini-
mum of 5 seconds.
2. Adjusting transmission ECMV electric cur- q [U]: Runs service menu
rent 5) On the adjustment menu selection screen,
a Adjustment is carried out four times auto- press [>] switch or [<] switch, and select
matically against the Hi, Lo, R, 1st, 2nd ECMV current adjustment item (02: ECMV
and 3rd valves respectively. TUNING).
1) Refer to "1. Preparation of operations for q [>]: To proceed to the next adjust-
adjusting transmission ECMV electric cur- ment menu
rent", and select the monitoring code of q [<]: To go back to the previous adjust-
transmission oil temperature. ment menu
q Monitoring code:
32500 (T/M OIL TEMP)
a At this time, do not start the engine.
6) With the adjustment menu selected, press

[U] switch and display the automatic com-
pensation (AUTO) or manual compensa-
2) Run the engine, set the machine to the tion (MANUAL) selection screen. Press
next condition, and confirm that the trans- [<] switch or [>] switch to select the auto-
mission oil temperature is between 60 –
matic compensation.
70 °C.
HM400-2 43
q [U]: To execute the adjustment menu 8) Normal and abnormal results are dis-
q [ > ]: To switch to the next compensa- played for each adjustment, therefore take
tion screen. action depending on the display.
q [ < ]: To switch to the next compensa-
tion screen.
q Compensation menu: AUTO
a The figure shows the state in which
the automatic compensation is
selected, therefore, [AUTO] is indi-
cated in the lower line. \ In the state in
which the manual compensation is
selected, [MANUAL] is indicated in
the lower line.
q Indicated code for the normal or ab-

normal result
Code Condition
OK Normal result
NG1 Out of compensation conditions
Abnormal
NG2 No fill
result
NG3 Over the compensation values
q If "OK" (normal result) is displayed:
Adjustment is done without error.
7) Confirm the machine condition again and q If "NG1" is displayed (out of compen-
press the [U] switch to start adjustment. sation condition):
q [U] switch: To start the adjustment Adjust the transmission oil tempera-
a The lower line display changes from ture exactly, and confirm the machine
"IP" to "IP ***". setting conditions again, then c a r r y
out the adjustment from procedure 1).
q If "NG2" (no fill) is displayed:
Carry out troubleshooting of failure
code [15S*MA][DDT*KA], and if the
condition is confirmed to be normal,
then start again from procedure 1)
(The symbol with * mark varies by
objective clutches).
q If "NG3" is displayed (compensation
value over):
Carry out troubleshooting of failure
code [15S*L1], and if the condition is
confirmed to be normal, then start i t
again from procedure 1) (The symbol
a Adjustments are carried out 4 times with * mark varies by objective clutch-
c o nti nu ou sl y f or ea ch o bj ec ti v e es).
clutch, and the below table is dis- 9) If the adjustments has been completed nor-
played. mally, the adjustment values are recorded
No. Valve 1st time 2nd time 3rd time 4th time in the transmission controller about 3 sec-
onds after the starting switch has been
1 LOW IP L-1 IP L-2 IP L-3 IP L-4
turned off.
2 HIGH IP H-1 IP H-2 IP H-3 IP H-4 a If the starting switch needs to be
3 REV IP R-1 IP R-2 IP R-3 IP R-4 turned ON soon after the adjustment,
4 1ST IP 1-1 IP 1-2 IP 1-3 IP 1-4 keep the starting switch in the OFF
position for more than 10 seconds as
5 2ND IP 2-1 IP 2-2 IP 2-3 IP 2-4
a precautionary measure then turn it
6 3RD IP 3-1 IP 3-2 IP 3-3 IP 3-4 ON.
44 HM400-2
3. Reset the transmission initial learning and a The current initialization state is dis-
implementation of learning played in the lower line.
a Before carrying out this adjustment item, q Initialization is done: INITIAL STATUS
be sure to implement "2. Transmission q Initialization is not yet done: TUNED
ECMV current adjustment". a If [TUNED] is indicated, proceed to
a Before proceeding to the learning, confirm the next procedure to initialize the
that the transmission oil temperature is at learning data.
the specified temperature referring to "1. a If the resetting operation is to be
Preparing operations for "Adjusting trans- aborted, press [t] switch to return to
mission ECMV electric current". (If adjust- the former screen.
ments are made at temperatures other q [t]: To return to the previous screen
than specified temperature, time lag or
gear shift shock may occur.)
k The learning should be carried out in
an area with a sufficient traveling dis-
tance, paying attention to the sur-
roundings for safety.
1) Select (TUNING) in the service menu
selection screen.
5) With the initial learning resetting screen

displayed, press the [U] switch to display
the initializing operation screen.
q [U] switch:
To execute the initial learning reset

[U] switch to display the adjustment menu
selection screen.
q [U]: To conduct the service menu.
3) With the adjustment menu selection
screen, confirm that the transmission trig-
ger adjustment item (01: TM TRIGGER) is
displayed.
6) With the initialization operation screen dis-

played, operate each of the switches [<],
[>] and [t] to execute initialization.
q [ <]: Select YES (move cursor)
q [ >]: Select NO (move cursor).
a After initializing, confirm that the dis-
play on the lower line indicates that
initialization is completed.
q Initialization is done: INITIAL STATUS
4) With the adjustment menu selected, press

the [U] switch to display the initial learn-
ing resetting screen.
q [U]: To execute the adjustment menu
HM400-2 45
10) With 2 items simultaneous monitoring se-

lected, press the [U] switch and display
the monitoring code input screen.
q [U]: Execute monitoring system and
function.
11) In the monitoring code input screen, oper-
ate each of the switches [>], [<], [U] and
[t], and directly input 2-digit monitoring
codes.
q [ < ]: Number at the cursor decreases
mined
q [t ]: Cursor moves to the left end / To
7) Return to service menu selection screen
return to the monitoring system
and select real time monitoring function
and function selection screen.
(REAL-TIME MONITOR).
q Monitoring code: 32500 and 38922
a Press [t] switch several times to
a Indicate the transmission oil tempera-
return to the service menu selection
ture in the upper row (32500) and
screen.
study condition of clutch trigger in the
lower row (38922) (0: not learned yet,
1: already learned).

tem and function selection screen.
12) Set AISS LOW switch to LOW.
q [U]: To conduct the service menu.
13) Start the engine, keep the gear shift lever
9) In the monitoring system and function
at N position for 10 seconds at the low
selection screen, press [>] switch or [<]
idle, then operate the gear shift lever as
switch to select 2 items simultaneous
follows.
monitoring (2 ITEMS).
a Gear shift lever operation:
q [>]: To proceed to next monitoring
N o R1 o N
system and function
14) Confirm the trigger learning display of R
q [<]: Go back to data for previous
clutch in the monitoring display.
monitoring system and function
a Proceed to the next step if the display
is "1".
a If the display is "0", repeat procedure
13) until it becomes "1".
a The * marked clutch display can be
either "0" or "1".
46 HM400-2
18) In the monitoring display, confirm finally

the trigger learning display of lower line.
a If displayed as drawing, the initial
learning has completed normally.
either "0" or "1".
15) Set the shift lever to the D position, travel

pressing the accelerator pedal, then shift
up from F2 – F4.
a Shift up: F2 o F3 o F4
a Be careful not to shift up to F5.
When shifted up to F5, redo from F2.
16) Release the accelerator pedal after travel- 19) Press [t] switch several times and com-
ing for 10 seconds at F4, then shift down plete service menu.
from F4 – F2 at coasting traveling. q [t]: To return to the previous screen
a Shift down: F4 o F3 o F2
a Do not operate the break during the
coasting travel.
17) In the monitoring display, confirm the trig-
ger learning display of Lo clutch and 1st
clutch.
a Learning operation is completed, if
the display is "1".
a If the display is "0", repeat procedure
15) - 16) until it becomes "1".
either "0" or "1".
HM400-2 47
[15] Filter and oil replacement time setting func- a Displayed maintenance item and
tion (MAINTENANCE MONITOR) function:
Machine monitor can set the maintenance intervals
No. Display Maintenance items and functions
for various filters and oil which become the base of
replacement time display for filter and oil. Also the 1 41:FUEL P FILT Fuel pre filter
machine monitor can activate or deactivate the dis- 2 01:ENG OIL Engine oil
play function. 3 02:ENG FILT Engine oil filter
4 12:TM OIL Transmission oil
Select the filter and oil replacement time set-
ting function (MAINTENANCE MONITOR) in 5 13:TM FILT Transmission oil filter
the service menu selection screen. 6 03:FUEL FILT Fuel main filter
7 06:CORR RES Corrosion resistor
8 17:BK OIL Brake oil
9 14:BK OIL FILT Brake oil filter
10 16:BK C FILT Brake cooling oil filter
11 04:HYD FILT Hydraulic oil filter
12 11:DIFF OIL Differential oil
13 08:FNL OIL Final drive oil
14 10:HYD OIL Hydraulic oil
15 INITIALIZE Setting default value for all items
Setting validity or invalidity for all
16 ALL ITEMS
items
2. Displaying and selecting the maintenance item
and function a No.1 – 14 are the maintenance items
1) With the service menu selected, press the where the setting is changed by item,
[U] switch to display the maintenance and No.15 – 16 are the functions
item and function selection screen. which allows to change the setting of
q [U]: Conduct the service menu. all items simultaneously.
a Display the item and function in the [*]
section.
2) If [>] switch or [<] switch is pushed while

the maintenance item and function selec-
tion screen is displayed, the maintenance 3. Display contents of the maintenance item
item and function will be displayed end- (Items No.1 – 14)
lessly in the order shown by the below If the maintenance item for filter or oil is
table. Select the item or the function selected, the following contents are displayed.
which will be used. 1: Code (2 digits)
q [>]: To proceed to next maintenance A: Filter and oil replacement time set items
item and function. 2: Remaining time to set replacement time
q [<]: To return to the previous mainte- 3: Number of times of replacement up to
nance item and function. present
48 HM400-2
3) When the interval time is completely

determined, the screen to confirm the
changes is displayed. Then, operate each
of the switches [<], [>] and [t].
q [ >]: Select NO (move cursor)
4. Changing the interval time by maintenance

item (Items No.1 – 14)
1) With the item selected on the mainte-
nance item and the function selection
screen to change the interval time (ex: P
FUEL FILT), press the [U] switch to dis-
play the interval change screen.
q [U]: Implement the function to 5. Set the function activation or deactivation by
change maintenance item. maintenance item (items No.1 – 14).
a The currently set interval is displayed 1) With the item selected on the mainte-
on the screen. nance item and function selection screen
a With this screen displayed, if the [>] (ex: FUEL P FILT) to change the activation
switch or the [<] switch is operated, or deactivation of the function, press the
the screen switches to the setting [U]switch to display the interval input
screen for activating or deactivating screen.
the maintenance item. q [U]: Implement the function to change
2) On the interval change screen, operate maintenance item.
each of the switches [>], [<], [U] and [t]
to input the interval time.
q [ < ]: Number at the cursor decreases.
mined.
q [ t]: To return to the service menu
selection screen.
a The time must always be input with 4
digits. For the time with less than 4
digits, input 0s in place of the vacant
number.
2) After displaying the screen to input inter-

vals, press the [>] switch or the [<] switch
to display the activation or deactivation
setting screen.
q [>]: Switch the setting screen.
q [<]: Switch the setting screen
a If the function is activated, it is dis-
played like the upper line. And if it is
deactivated, it is displayed like the
lower line.
HM400-2 49
3) After the activate or deactivate setting the [U] switch to display the all item
screen is displayed, check the present default value setting screen.
setting status and the contents of change. q [U]: Implement the function to set the
Then operate each of the switches [U] default values of all the items.
and [t].
q [U]: Switch to the change confirma-
tion screen
q [t]: To return to the maintenance
i te m an d fu nc ti on s e le ct io n
screen.
q [< ]: Switch to the interval change
screen.
2) Display the all item default value setting

screen and operate each [<], [>] and [t]
switches.
q [ >]: Select NO (move cursor)
4) When the change confirmation screen is

displayed, operate each [<], [>] and [t]
switches.
q [ < ]: Select YES (move cursor)
q [ > ]: Select NO (move cursor)
a If the intervals for all the items are

changed in an item, all the items are
set to their respective default values,
regardless of the ON or OFF state of
each item.
a The rest of the set time of the timer is
set to the [default value/elapsed time
after the previous replacement].
a If the timer which has been OFF is a The number of resetting times is kept
turned ON, the interval is set to the at the value before the default was
value before it was turned OFF and set.
the rest of set time of the timer is a Each item is set turned ON.
reset. The number of resetting times
is set to the value before it was turned 7. Setting the function activation or deactivation
OFF. for all the items (function No.16)
1) With the activation or deactivation setting
6. Setting default values of interval time for all for all items selected (ALL ITEMS) on the
items (function of No.15) maintenance item and function selection
1) With all item default value setting (INI- screen, press the [U] switch to display the
TIALIZE) selected on the maintenance all items activation or deactivation setting
item and function selection screen, press screen.
50 HM400-2
q [U]: Implement the function to set

activation or deactivation of all
the items.
4) When the change confirmation screen is

displayed, operate each [<], [>] and [t]
switches.
2) After the all items activation or deactiva- q [ <]: Select YES (move cursor)
tion setting screen is displayed, press the q [ >]: Select NO (move cursor)
[>] switch or the [<] switch to display the q [t]: Execute YES or NO
activation setting or deactivation setting
screen.
q [>]: Switch the setting screen.
q [<]: Switch the setting screen
a To deactivate all the items, display the
upper line setting screen (OFF), and
to activate all the items, display the
lower line setting screen (OFF).
3) Confirm the setting screen, press the
[U] switch or the [t] switch to display
the change confirmation screen.
q [U]: To switch to the change confir-
mation screen.
q [ t]: To return to the maintenance
i te m an d fu nc ti on s e le ct io n
screen.
a If deactivation of all the items (OFF) is
set, it will stop the maintenance func-
tion of all the items, regardless of the
setting by the maintenance item.
a If activation of all the items (ON) is
set, the maintenance function of all
the items starts to work regardless of
setting by the maintenance item and
the interval is set to the previous time
before the interval has been deacti-
vated.
The timer is reset simultaneously and
it restarts to count from 0 h.
The number of resetting times is set
to the value before it was turned OFF.
HM400-2 51
Table of filter and oil replacement time set items

Replacement frequency
No. System and function Code Display Remarks
(Default value)
1 Fuel pre filter 41 FUEL P FILT 0500
2 Engine oil 01 ENG OIL 0500
3 Engine oil filter 02 ENG FILT 0500
4 Transmission oil 12 TM OIL 1000
5 Transmission oil filter 13 TM FILT 1000
6 Fuel main filter 03 FUEL FILT 1000
7 Corrosion resistor 06 CORR RES 1000
8 Brake oil 17 BK OIL 1000
9 Brake oil filter 14 BK OIL FILT 1000
10 Brake cooling oil filter 16 BK C FILT 1000
11 Hydraulic oil filter 04 HYD FILT 2000
12 Differential oil 11 DIFF OIL 2000
13 Final drive oil 08 FNL OIL 2000
14 Hydraulic oil 10 HYD OIL 4000
All item simultaneous
15 Setting default value for all items (None) INITIALIZE —
setting function
All item simultaneous
16 Setting validity or invalidity for all items (None) ALL ITEMS —
setting function
52 HM400-2
[16] Operation information display function a There are three types of information
(OPERATION INFO) screen.
Machine monitor can display the fuel consumption
per mile and per time, the fuel consumption per any 4. Information to be displayed (screen 1 – 3)
accumulated time and the travel distance, and the Above: Fuel consumption per km or mile from
fuel consumption during any accumulated time and the last reset point (distance unit is km
its accumulated time. or mile and it depends on the setting of
a Fuel consumption value is the integration of the integrated odometer in the opera-
the targeted injection rate signal which is sent tor mode).
from the engine controller. It is not the mea- Maximum display value:
surement of the actual fuel consumption. 99999.9 L/km (L/mile)
Therefore the displayed fuel consumption is Below: Fuel consumption per time started
used as a guide value. from the last reset point
Maximum display value: 99999.9 L/h
Select the operation information display func-
tion (OPERATION INFO) on the service menu
selection screen.
Above: Integrated fuel consumption started

from the last reset point
Maximum display value: 9999999.9 L
Below: Accumulated travel distance from the
2. Displaying the operation information
last reset point (travel distance unit is
With the service menu selected, press the
km or mile and it depends on the set-
[U]switch and display the operation informa-
ting of the integrated odometer in the
tion and item selection screen.
operator mode).
Maximum display value:
9999999.9 km (mile)
3. Selecting displayed information

With the operation information and item selec-
Above: Integrated fuel consumption started
tion screen displayed, operate the [>] switch or
from the last reset point
the [<] switch to select the information screen
Maximum display value: 9999999.9 L
to display.
Below: Elapsed time from the last reset point
q [>]: To display the next information
Maximum display value: 9999999.9 h
screen.
q [<]: To display the previous informa-
tion screen.
HM400-2 53
2) After the fuel consumption correction

5. Resetting displayed information
screen is displayed, press the [U] switch
1) With any information screen displayed,
or the [t] switch to switch to the correction
press the [U] switch to display the reset
value input screen.
screen.
q [U]: Switch to the correction value
q [U]: Switch to the reset screen.
input screen
2) After the reset screen is displayed, press
q [t ]: To return to the service menu
the [U] switch or the [t] switch and exe-
screen
cute or cancel the reset.
q [U]: Implement resetting.
q [ t]: Cancel resetting
a When the resetting is carried out, all
the information goes to "0", and the
monitoring starts newly from that
point of time (Monitoring is only con-
ducted while engine is running.)
a If the [>] switch or the [<] switch is
operated with this screen displayed,
the screen is switched to the fuel con-
sumption correction screen.
3) After displaying the compensation value

input screen, operate each of the switches
[>], [<], [U] and [t] to input the compen-
sation value directly.
q [ > ]: To switch the cursor symbol (+/-)
/ Number increases.
q [ < ]: To switch the cursor symbol (+/-)
/ Number decreases.
q [U]: Sign/number at the cursor is
determined.
q [t ]: Return to the fuel correction
screen
6. Correction of integrated fuel consumption a The correction value at the plant
a When there is the difference between before shipment is [+/-00.0%] (In
the integrated fuel consumption (L) in case of inputting 00.0, +/- does not
display and the actually measured matter.)
fuel consumption, correct it in the fol- a The compensation value can be input
lowing way. within the range of [-50.0% –
1) With the reset screen displayed, press the +50.0%].
[>] switch or the [<] switch to display the
fuel consumption correction screen.
q [>]: Switch the displayed screen
q [<]: Change the displayed screen
54 HM400-2
[17] Option selection function

(OPTIONAL SELECTION)
Machine monitor can set and adjust various
optional devices which have been installed or
removed.
a The operating method of this function refers to
the item of "Setting and adjusting various
equipment".
[18] Model selection function (MACHINE)

Machine monitor is common among many models,
and if the machine monitor is replaced, select the
same model as the one currently installed.
a The operating method of this function refers to
the item of "Setting and adjusting various
equipment".
[19] Initializing function (INITIALIZE)

a This function is exclusive for the plant, and is
not used for service.
HM400-2 55
How to start operation of 3) When about 3 to 5 seconds elapsed after

the starting switch was set to ACC, make
KOMTRAX terminal 1 sure that the 7-segment indicator lamp
In the case where the KOMTRAX terminal has changes to hyphen “–” on the KOMTRAX
been installed at the plant before shipment: terminal.
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
q Domestic (Japan): The setting work has
already completed.
q Other than Japan: Execute "3. Request of
opening station of ORBCOMM terminal".
In the case where KOMTRAX terminal is retrofit-

ted on machine after shipment:
a Implement the following procedure in the case
where the KOMTRAX terminal is retrofitted after
shipment of the machine (retrofitted machine).
q Domestic (Japan): Execute "1. Opening
station inspection of machine side" and "2.
Application of start of use".
q Other than domestic (Japan): Execute "1.
Opening station inspection of machine
side" and "2. Application of start of use"
and "3. Opening station request of ORB-
COMM terminal".
How to start operation

1. Station opening check in machine side
a Complete steps 3) to 5) within 60 sec-
onds. If 60 seconds or above elapsed,
begin with step 1) again. 4) Disconnect inspection connector 1, and
1) Turn OFF the starting switch and then, wait for about 3 to 5 seconds as it is.
a ft e r m a k i n g s u r e 5 s e c o n d s h a v e a Ensure that the connector is discon-
elapsed, proceed to the next step. nected.
2) Visually check that check connectors 1 5) Reconnect inspection connector 1, and
and 2 are connected. wait for about 3 to 5 seconds as it is.
q Check connector 1: CHK1 a If the KOMTRAX terminal detects that
q Check connector 2: CHK2 the connector was disconnected and
connected, the dot on the 7-segment
indicator lamp blinks a few times.
56 HM400-2
6) Make sure that the 7-segment indicator 7) Turn the starting switch to START position
lamp is indicated normally on the for about 3 to 5 seconds, and make sure
KOMTRAX terminal. that the engine does not start.
a If so, the 7-segment indicator lamp will a If the engine starts, re-execute the
indicate characters “d”, “0”, and “–” procedure above from step 1).
repeatedly for 30 seconds after step 5) a Do not return the starting switch to
was ended. OFF position.
a Those characters, even if displayed 8) Turn the starting switch from ACC position
normally, will change to a character to START position again, and make sure
other than hyphen “–”after 30 sec- that the engine starts.
onds or above elapsed. 9) Make sure that the KOMTRAX terminal's
The display may change to a charac- indicator lamps are normally turned on.
ter other than “0” even within 30 sec- a Move on to the next step if you can
onds. check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trou-
ble and reception trouble] is indi-
cated, check if there is any
abnormality on the GPS antenna/
cable or communication antenna/
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Network trouble] is indicated,
check the display of [LED-C4] refer-
ring to “Lamp display of KOMTRAX
terminal”. If the CAN is not recog-
nized, check the CAN harness of the
a As [Normal] is indicated, proceed to KOMTRAX terminal, and then if there
the next step. is any abnormality, repair it and start
a If “–” remains displayed, execute from procedure 1) again.
steps 1) to 5) again.
HM400-2 57
[A]: Normal
[B]: GPS position data detection trou-
ble
[C]: Reception trouble
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
12) When station opening check ended nor-

m a l l y, a c o m m u n i c a t i o n w i t h t h e
KOMTRAX server starts automatically,
and settings are stored in KOMTRAX.
(This requires about 25 minutes to 4
hours.)
a During this time, you may turn the
starting switch off and start the engine.
a During the communication and check
above, you should park the machine
outside to enable a frequent communi-
cation with the ORBCOMM satellite.
The station opening check may not be
completed in doors that cause radio
waves from the satellite to be inter-
cepted.
10) Turn the starting switch OFF.

11) Make sure that the 7-segment indicator
lamp is displayed normally after 5 seconds
elapsed.
a When [Normal] appears, station open-
ing check is completed.
a If [Abnormal] appears, station open-
ing check does not end normally, so
you should perform the procedure
above from step 1) again.
a If station opening check ends nor-
mally, it should not be rechecked.
58 HM400-2
2. Application for the start of use 3. Opening station request of ORBCOMM ter-
a Application for the start of use is made minal
only after the sign-up test on the machine Fill in the necessary matters in the paper of
side is finished. "opening request of ORBCOMM terminal" and
1) Notify to the KOMTRAX operations ad- send KOMTRAX service hotline by fax or mail.
ministrator the following information con-
cerning the machine whose sign-up test
on the machine is completed.
(1) Information on the machine whose
sign-up test on the machine system is
completed (model, model number
and serial number).
(2) Part number and serial number of the
KOMTRAX terminal
(3) Reading of the service meter when
the KOMTRAX terminal is installed
(0.1 h unit)
2) The KOMTRAX operations administrator

registers the body using a KOMTRAX cli-
ent personal computer.
a For the procedure, see the following;
In Japan: "KOMTRAX instruction manual
for responsible person for operation"
Out of Japan: "Global KOMTRAX Web
Reference Manual" (For key person)
HM400-2 59
60 HM400-2
Lamp display of KOMTRAX terminal 1
CPU LED 7 segments and dot for CPU

1. LED-C1 (R signal, ACC signal) 7. 7 segments (number of mails not yet sent)
2. LED-C2 (Starting output status) 8. Dot (GPS positioning status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (Condition of CAN communication)
5. LED-C5 (downloading and writing status)
6. LED-C6 (downloading and writing status)
HM400-2 61
In the KOMTRAX system, various information and processing details are displayed on the LEDs on the
upper surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the fol-
lowing checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the vehicle bodies should be completed before using
KOMTRAX system.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be disconnected or damaged.
q The communication antenna cable should not be broken and be connected normally with the
KOMTRAX terminal.
q The GPS antenna should not be disconnected or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Display contents of LED for CPU
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
Display
No. LED Name and function Display contents
(refer to *1)
Lighting on Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
1 LED-C1 signal and alternator
R signal Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
Lighting off Starting switch ACC signal: OFF, alternator R signal: OFF
Engine control signal Lighting on Engine control signal: ON
2 LED-C2
status Lighting off Engine control signal: OFF
Lighting on S-NET: connected, starting switch C signal: OFF
S-NET connection Fast blinking Starting switch C signal: ON
3 LED-C3 status and starting
switch C signal status Slow blinking (Not used)
Lighting off S-NET: disconnected, starting switch C signal: OFF
Lighting on CAN: active (fuel sensor: inactive)
Fast blinking CAN: active (fuel sensor: active)
4 LED-C4 CAN status
Slow blinking CAN: inactive (fuel sensor: active)
Lighting off CAN: inactive (fuel sensor: inactive)
Downloading and writing status (special function for system
5 LED-C5 Downloading and One side is ON
administrator)
writing status
6 LED-C6 Both lighting off Normal operation mode
* 1: Blinking type and time

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 second cycle
62 HM400-2
2. Display contents of 7-segment and dot for CPU

a LED displays should be checked with the starting switch ON.
Display
No. LED Name and function Display contents
(refer to *2)
Number means number of mails not yet sent (9 is displayed
0–9
Number of mails not even if there are more than 9 mails). Lighting on indicates status
lighting on
7 seg- yet sent and waiting acquiring satellite.
7
ments status acquiring Number means number of mails not yet sent (9 is displayed
satellite 0–9
even if there are more than 9 mails). Fast blinking means
fast blinking
waiting status acquiring satellite.
GPS positioning has been completed. (Position has been
Lighting on
GPS positioning recognized. Refer to *3.)
8 Dot
status GPS positioning has not been completed. (Position has not
Lighting off
been recognized. Refer to *3.)
* 2: Blinking type and time

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 second cycle
* 3: Supplementary explanation of GPS positioning status
It may take more than 1 minute from turning on the starting switch to the completion of positioning even
in an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of radio
waves.
HM400-2 63
Pm Clinic check sheet 1
64 HM400-2
HM400-2 65
66 HM400-2
Initial setting of payload meter 1

In the following cases, perform "setting of option selection of machine monitor" and "setting with VHMS ini-
tialization manual (tool)" according to Table 1.
1. When the payload meter in the VHMS or card-type payload meter (PLM ) is installed for the first time
2. When the payload meter in the VHMS or card-type payload meter (PLM ) is removed
3. When the VHMS controller or transmission controller is replaced
4. When setting of VHMS controller (PLM ) is changed
Table 1
Setting with VHMS initial setting manual (tool) (*1)

PLM Card-type
payload Payload Date
VHMS function in meter (PLM)
controller VHMS meter Variation Time
function Model Type Time difference
controller (PLM- ) code
(GMT)
Summer time
Installed Not installed Not installed Not installed ST

HD465 Set
Installed Not installed Installed Installed HD605 – 7E0 P2 properly
Installed Installed Not installed Installed PV
(*1) For setting of the model, type, variation code, etc., see the VHMS initial setting manual (Tool)
When there is not a problem in installation and wiring of the payload meter but there are the following prob-
lems, check the above setting again.
1. Items related to the payload meter are not displayed on the machine monitor.
"The payload is not displayed when the machine is loaded and stopped", "There are not the manus
related to the payload meter on the match marks", etc.
a In the following cases, perform "setting of option selection of machine monitor" and "setting with
VHMS initialization manual (tool)" according to Table 1.
2. While the payload meter in the VHMS is not set, there are the menus related to the payload meter on
the machine monitor.
a In the following cases, perform "setting of option selection of machine monitor" and "setting with
VHMS initialization manual (tool)" according to Table 1.
3. While the payload meter in the VHMS is set, the payload does not match to the lighting condition of the
red lamp of the outside indicator lamps.
a Wrong setting of the model and serial No. with the VHMS initial setting tool.
4. The storage place of the data file made by the download software is not found.
a Wrong setting of the model and serial No. with the VHMS initial setting tool.
5. Data cannot be downloaded.
a Wrong setting of the model, serial No., and variation code with the VHMS initial setting tool.
6. Date and time of the downloaded data are wrong.
a Wrong setting of the date and time with the VHMS initial setting tool.
HM400-2 67

© 2009 KOMATSU
All Rights Reserved
68 HM400-2
SEN01107-02
HM400-2

HM400-2 2001 and up
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting........................................................................................................... 3
Check before troubleshooting ......................................................................................................................... 4
Classification and procedures for troubleshooting .......................................................................................... 5
Connection table for connector pin numbers .................................................................................................. 8
T-branch box and T-branch adapter table ..................................................................................................... 44
HM400-2 1
SEN01107-02 40 Troubleshooting
Points to remember when troubleshooting 1

k Stop the machine in a level ground, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 4) Other maintenance items can be checked
hurry to disassemble the components. externally, so check any item that is con-
If components are disassembled immediately sidered to be necessary.
any failure occurs:
4. Confirming failure
q Parts that have no connection with the fail-
Confirm the extent of the failure yourself, and
ure or other unnecessary parts will be dis-
judge whether to handle it as a real failure or
assembled.
as a problem with the method of operation, etc.
q It will become impossible to find the cause
a When operating the machine to reenact
of the failure.
the troubleshooting symptoms, do not
It will also cause a waste of manhours, parts,
carry out any investigation or measure-
or oil or grease, and at the same time, will also
ment that may make the problem worse.
lose the confidence of the user or operator.
For this reason, when carrying out trouble- 5. Troubleshooting
shooting, it is necessary to carry out thorough Use the results of the investigation and inspec-
prior investigation and to carry out trouble- tion in Items 2 – 4 to narrow down the causes
shooting in accordance with the fixed proce- of failure, then use the troubleshooting flow-
dure. chart to locate the position of the failure
exactly.
2. Points to ask user or operator
a The basic procedure for troubleshooting is
1) Have any other problems occurred apart
as follows.
from the problem that has been reported?
1] Start from the simple points.
2) Was there anything strange about the
2] Start from the most likely points.
machine before the failure occurred?
3] Investigate other related parts or infor-
3) Did the failure occur suddenly, or were
mation.
there problems with the machine condition
before this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure Even if the failure is repaired, if the root cause
occur? of the failure is not repaired, the same failure
5) Had any repairs been carried out before will occur again.
the failure? To prevent this, always investigate why the
When were these repairs carried out? problem occurred. Then, remove the root
6) Has the same kind of failure occurred cause.
before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the
machine?
2) Make checks before starting day's work.
3) Make checks of other items.
2 HM400-2
Sequence of events in troubleshooting 1
HM400-2 3
Check before troubleshooting 1
Item Criterion Remedy

1. Check of level and type of fuel — Add fuel
2. Check of fuel for foreign matter — Clean and drain
3. Check of coolant level Between FULL – LOW Add coolant
4. Check of dust indicator for clogging Other than red Clean or replace
5. Check of oil level in engine oil pan Between H – L Add oil
Lubricating 6. Check of engine oil filter — Replace

oil and 7. Check of oil level in transmission case Between H – L Add oil
coolant 8. Check of transmission oil filter — Replace
9. Check of oil level in hydraulic tank Between H – L Add oil
10. Check of hydraulic oil strainer — Clean
11. Check of hydraulic oil filter — Replace
12. Check of oil level in final drive case — Add oil
13. Check of oil level in differential case — Add oil
Hydraulic 1. Check for abnormal sound and smell — Repair
and 2. Check for oil leakage — Repair
mechanical
components 3. Execution of air bleeder operation — Bleed air
1. Check of battery terminal wiring for looseness
— Retighten or replace
and corrosion
2. Check of alternator terminal wiring for looseness
and corrosion
3. Check of starting motor terminal wiring for loose-
ness and corrosion
4. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
5. Check of electrolyte level Between H – L Add or replace
Electrical 6. Check of wiring for discoloration, burn, and peel-
— Repair or replace
components ing of cover
and parts 7. Check for removal of wire clamp and sag of wire — Repair
8. Check of wiring for wetness (Check connectors
— Dray
and terminals in particular)
9. Check for trip of circuit breaker and breakage
— Replace
and corrosion of fuse
10. Check of alternator voltage (with engine speed at 27.5 – 29.5 V after opera-
Replace
medium or higher) tion of several minutes
11. Check of operating sound of battery relay (when
— Replace
starting switch is turned ON or OFF)
4 HM400-2
Classification and procedures for troubleshooting 1

Classification for troubleshooting
Type Contents
Display of code Troubleshooting by failure code
E mode Troubleshooting for electrical system
H mode Troubleshooting for hydraulic and mechanical system
S mode Troubleshooting for engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
HM400-2 5
Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomenon looking like trouble Display
E mode H mode S mode
of code
Action code/Failure code
1 Action code and failure code are displayed on machine monitor
When fault history is checked, failure code is displayed in mechanical Accord-
2
system fault history ing to fail-
When fault history is checked, failure code is displayed in electrical ure code
3
system fault history
Phenomena related to engine
4 Starting performance is poor S-1
5 Engine does not start E-1 S-2
6 Engine does not pick up smoothly S-3
7 Engine stops during operations S-4
8 Engine does not rotate smoothly S-5
9 Engine lacks output (or lacks power) S-6
10 Exhaust smoke is black (incomplete combustion) S-7
11 Oil consumption is excessive (or exhaust smoke is blue) S-8
12 Oil becomes contaminated quickly S-9
13 Fuel consumption is excessive S-10
14 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
15 Oil pressure drops S-12
16 Oil level rises (Entry of coolant/fuel) S-13
17 Coolant temperature becomes too high (overheating) S-14
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
20 Preheater does not operate E-2
Phenomena related to power train
21 Machine does not start H-1
22 Travel is not smooth H-2
23 Lockup is not reset H-3
24 Start shock and gear shift shock are abnormally large H-4
25 Gear is not shifted up H-5
26 Travel speed or power is low H-6
27 Start and gearshift time lag is large H-7
28 Torque converter oil temperature is high H-8
29 Torque converter oil temperature is low H-9
Phenomena related to brake
30 Front brake does not work fully H-10
31 Center brake does not work fully H-11
32 Rear brake does not work fully H-12
Phenomena related to steering system
33 Steering wheel is heavy H-13
34 Steering wheel does not move H-14
35 Steering wheel waggle H-15
6 HM400-2
Troubleshooting
No. Phenomenon looking like trouble Display
E mode H mode S mode
of code
Phenomena related to dump body
36 Dump body raising speed is low H-16
37 Dump body does not move H-17
38 Hydraulic drift of dump body is large H-18
Phenomena related to machine monitor/panel switch
39 When starting switch is turned ON, machine monitor displays nothing E-3
When starting switch is turned OFF, machine monitor cannot be
40 E-4
operated
41 Alarm buzzer does not stop sounding E-5
Machine monitor does not normally display gauges, caution lamps, and
42 E-6
character display section
43 Display of character display section cannot be changed E-7
44 Power mode selection function does not operate normally E-8
45 AISS function does not operate normally E-9
Right and left differential lock function does not operate normally
46 E-10
(Differential lock-up specification)
47 Interaxle differential lock-up function does not operate normally E-11
48 Display of seat belt caution lamp is abnormal E-12
49 Turn signal lamps and pilot lamps do not operate normally E-13
50 Night lighting is abnormal E-14
51 Backup lamp and backup buzzer operate abnormally E-15
52 Emergency steering system does not operate E-16
HM400-2 7
Connection table for connector pin numbers 1

(Rev. 2008.09)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
8 HM400-2
HM400-2 9
10 HM400-2
HM400-2 11
12 HM400-2
HM400-2 13
14 HM400-2
HM400-2 15
16 HM400-2
HM400-2 17
18 HM400-2
HM400-2 19
20 HM400-2
HM400-2 21
22 HM400-2
HM400-2 23
24 HM400-2
HM400-2 25
26 HM400-2
HM400-2 27
28 HM400-2
HM400-2 29
30 HM400-2
HM400-2 31
32 HM400-2
HM400-2 33
34 HM400-2
HM400-2 35
36 HM400-2
HM400-2 37
38 HM400-2
HM400-2 39
40 HM400-2
HM400-2 41
42 HM400-2
HM400-2 43
T-branch box and T-branch adapter table 1

(Rev. 2008.02)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 — q q
799-601-7090 Adapter for M 2 M2P q q q q
44 HM400-2
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
HM400-2 45
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9320 T-box (for ECONO) 24 q q q

799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Adapter for oil pressure
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atmosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2-4 and DTM2 3, — q
4
“*” Shows not T-adapter but socket.
46 HM400-2
HM400-2 47

© 2009 KOMATSU
All Rights Reserved
48 HM400-2
SEN01262-00
HM400-2

HM400-2 2001 and up
Troubleshooting by failure code, General
Troubleshooting by failure code, General ....................................................................................................... 2
Failure codes table............................................................................................................................... 2
Before troubleshooting by failure code............................................................................................... 10
Information in troubleshooting table ................................................................................................... 18
HM400-2 1
Troubleshooting by failure code, General 1

Failure codes table 1
Failure Applicable Action History Reference
codes Failure contents equipments code classification manual
Mechanical
1500L0 Detecting dual engagement TM E03 system
Mechanical
15B0NX T/M oil filter clogging TM E01 system
15F0KM R o F gear shift abuse 1 TM – Mechanical
system
15F0MB R o F gear shift abuse 2 TM – Mechanical
system
15F7KM T/M forward clutch abuse TM – Mechanical
system
Electrical
15G0MW R clutch system failure (Slip is detected) TM E03 system
Mechanical
15G7KM T/M reverse clutch abuse TM – system
Electrical
15H0MW Hi clutch system failure (Slip is detected.) TM E03 system
Electrical Troubleshooting
15J0MW Lo clutch system failure (Slip is detected.) TM E03 system by failure code,
Electrical Part 1
15K0MW 1st clutch system failure (Slip is detected.) TM E03 SEN01108-00
system
15L0MW 2nd clutch system failure (Slip is detected.) TM E03 Electrical
system
15M0MW 3rd clutch system failure (Slip is detected.) TM E03 Electrical
system
Electrical
15SBL1 R clutch pressure control valve failure TM E03 system
Electrical
15SBMA R clutch pressure control valve failure TM E03 system
Electrical
15SCL1 Hi clutch pressure control valve failure TM E03 system
15SCMA TM E03 Electrical
Hi clutch pressure control valve failure system
15SDL1 Lo clutch pressure control valve failure TM E03 Electrical
system
15SDMA Lo clutch pressure control valve failure TM E03 Electrical
system
Electrical
15SEL1 1st clutch pressure control valve failure TM E03 system
Electrical
15SEMA 1st clutch pressure control valve failure TM E03 system
Electrical
15SFL1 2nd clutch pressure control valve failure TM E03 system
15SFMA TM E03 Electrical
2nd clutch pressure control valve failure system
15SGL1 3rd clutch pressure control valve failure TM E03 Electrical
system Troubleshooting
15SGMA 3rd clutch pressure control valve failure TM E03 Electrical by failure code,
system Part 2
Electrical SEN01109-00
15SJMA L/U clutch pressure control valve failure TM E03 system
Inter axle differential lock-up clutch pressure control Electrical
15SKMA TM E01 system
valve failure
Front wheels differential lockup control valve system Electrical
2A62L1 BK E01
failure system
2A62LH Front wheels differential lockup control valve system BK E01 Electrical
failure system
2B62L1 Rear wheels differential lockup control valve system BK E01 Electrical
failure system
2 HM400-2
Failure Failure contents Applicable Action History Reference

codes equipments code classification manual
2B62LH Rear wheels differential lockup control valve system BK E01 Electrical
failure system
2C4MNX Retarder cooling filter clogging MON E01 Mechanical
system
2F00KM Dragging of parking brake TM – Mechanical
system
Mechanical
2G42ZG Decrease of accumulator oil pressure (Front) BK E03 system
Mechanical
2G43ZG Decrease of accumulator oil pressure (Rear) BK E03 system
(989A00) Engine over run prevention activated MON E02 –
A570NX Engine oil filter clogging TM E01 Mechanical
system
AA10NX Clogged air cleaner MON E01 Mechanical
system
AB00MA Failure of battery charge circuit TM E03 Electrical
by failure code,
Mechanical Part 2
B@BAZG Engine oil pressure is too low. ENG E03 system SEN01109-00
Mechanical
B@BAZK Engine oil level is too low. TM E01 system
Mechanical
B@BCNS Engine overheat ENG E02 system
B@BCZK Coolant level is too low. MON E01 Mechanical
system
B@C6NS Overheat of brake cooling oil temperature (Front) MON E02 Mechanical
system
B@C7NS Overheat of brake cooling oil temperature (Rear) MON E02 Mechanical
system
B@C8NS Overheat of brake cooling oil temperature (Center) MON E02 Mechanical
system
Mechanical
B@CENS Overheat of T/C fluid temperature MON E02 system
Mechanical
B@JANS Overheat of steering oil temperature TM E02 system
Electrical
CA111 Abnormality in engine controller ENG E03 system
CA115 Abnormal engine Ne and Bkup speed sensors ENG E03 Electrical
system
CA122 Charge pressure sensor too high ENG E03 Electrical
system
CA123 Charge pressure sensor too low ENG E03 Electrical
system
Electrical
CA131 Throttle sensor tool high ENG E03 system
Electrical
CA132 Throttle sensor too low ENG E03 system Troubleshooting
Electrical by failure code,
CA135 Engine oil pressure sensor too high ENG E01 system Part 3
CA141 Engine oil pressure sensor too low ENG E01
system
CA144 Coolant temperature sensor too high ENG E01 Electrical
system
CA145 Coolant temperature sensor too low ENG E01 Electrical
system
Electrical
CA153 Charge temperature sensor too high ENG E01 system
Electrical
CA154 Charge temperature sensor too low ENG E01 system
Electrical
CA187 Sensor power source 2 too low ENG E03 system
HM400-2 3

CA221 Atmospheric pressure sensor too high ENG E01 Electrical
system
Electrical
CA222 Atmospheric pressure sensor too low ENG E01 system
Electrical
CA227 Sensor power source 2 too high ENG E03 system
Mechanical
CA234 Engine overspeed ENG E02 system
CA238 Abnormal power source for Ne speed sensor ENG E03 Electrical
system
CA263 Fuel temperature sensor too high ENG E01 Electrical
system
CA265 Fuel temperature sensor too low ENG E01 Electrical
system
Electrical
CA271 PCV1 short circuit ENG E03 system
Electrical
CA272 PCV1 disconnection ENG E03 system
Electrical
CA273 PCV2 short circuit ENG E03 system Troubleshooting
CA274 PCV2 disconnection ENG E03 system Part 3
CA322 Disconnection or short circuit in injector No.1(L No.1) ENG E03
system
CA323 Disconnection or short circuit in injector No.5 ENG E03 Electrical
(L No.5) system
CA324 Disconnection or short circuit in injector No.3 ENG E03 Electrical
(L No.3) system
Disconnection or short circuit in injector No.6 Electrical
CA325 (L No.6) ENG E03 system
CA342 Abnormal engine controller data consistency ENG E03 Electrical
system
CA351 Abnormal injector drive circuit ENG E03 Electrical
system
CA352 Sensor power source 1 too low ENG E03 Electrical
system
Electrical
CA386 Sensor power source 1 too high ENG E03 system
Electrical
CA431 Abnormal idle validation switch ENG E01 system
Electrical
CA432 Abnormal process with idle validation ENG E03 system
CA441 Power source voltage too low ENG E03 Electrical
system
CA442 Power source voltage too high ENG E03 Electrical
system
CA449 Common rail pressure too high 2 ENG E03 Electrical Troubleshooting
system by failure code,
Electrical Part 4
CA451 Common rail pressure sensor too high ENG E03 system SEN01111-00
Electrical
CA452 Common rail pressure sensor too low ENG E03 system
Electrical
CA553 Common rail pressure too high 1 ENG E03 system
CA554 Common rail pressure sensor: in range error ENG E03 Electrical
system
CA559 Loss of pressure feed from supply pump 1 ENG E03 Electrical
system
4 HM400-2

CA689 Abnormal engine Ne speed sensor ENG E03 Electrical
system
Electrical
CA731 Abnormal engine Bkup speed sensor phase ENG E03 system
Electrical
CA757 Loss of all engine controller data ENG E03 system
Electrical
CA778 Abnormal engine Bkup speed sensor ENG E03 system
CA1228 Abnormal EGR valve servo 1 ENG E03 Electrical
system
CA1625 Abnormal EGR valve servo 2 ENG E03 Electrical
system
CA1626 Short circuit of bypass valve solenoid drive ENG E03 Electrical
system
Electrical
CA1627 Disconnection in bypass valve solenoid drive ENG E03 system
Electrical
CA1628 Abnormal bypass valve servo 1 ENG E03 system
Electrical
CA1629 Abnormal bypass valve servo 2 ENG E03 system
Electrical
CA1631 Bypass valve lift sensor too high ENG E03 system
CA1632 Bypass valve lift sensor too low ENG E03 Electrical Troubleshooting
system by failure code,
Electrical Part 4
CA1633 Abnormal KOMNET ENG E03 SEN01111-00
system
CA1642 EGR inlet pressure sensor too low ENG E01 Electrical
system
Electrical
CA1653 EGR inlet pressure sensor too high ENG E01 system
Electrical
CA2185 Throttle sensor power source too high ENG E03 system
Electrical
CA2186 Throttle sensor power source too low ENG E03 system
CA2249 Loss of pressure feed from supply pump 2 ENG E03 Electrical
system
CA2271 EGR valve lift sensor too high ENG E03 Electrical
system
CA2272 EGR valve lift sensor too low ENG E03 Electrical
system
Electrical
CA2351 EGR valve solenoid drive short circuit ENG E03 system
Electrical
CA2352 EGR valve solenoid drive disconnection ENG E03 system
Electrical
CA2555 Disconnection in intake air heater relay ENG E01 system
CA2556 Short circuit in intake air heater relay ENG E01 Electrical
system
DAF9KM Wrong connection of connector MON E03 Electrical
system
DAFRKR Abnormal CAN communication (machine monitor) TM E03 Electrical
system
Electrical
DAQ0KK Power source voltage too low TM E03 system
Troubleshooting
DAQ0KT Abnormal non volatile memory TM E01 system Part 5
DAQ2KK Solenoid power supply system failure TM E03 system
(DAQ9KQ) Inconsistent model selection (T/M controller) MON E03 –
DAQRKR Abnormal CAN communication (T/M controller) MON E03 Electrical
system
(DAQRMA) Inconsistent option setting (T/M controller) MON E03 –
HM400-2 5

DB10KT Abnormal non volatile memory BK E03 Electrical
system
Electrical
DB12KK Solenoid power supply system failure BK E03 system
Electrical
DB13KK Battery direct power supply too low BK E03 system
(DB19KQ) Inconsistent model selection (T/M controller) MON E03 –
(DB1QMA) Inconsistent option setting (T/M controller) MON E03 –
DB1RKR Abnormal CAN communication (T/M controller) TM E03 Electrical
system
DB2RKR Abnormal CAN communication (engine controller) TM E03 Electrical
system
Electrical
DD1ML4 Inconsistent signal of axle connected retarder switch TM E01 system
Electrical
DDTHKA Failure of flow detection valve for Hi clutch TM E03 system
Electrical
DDTJKA Failure of flow detection valve for Lo clutch TM E03 system
Electrical
DDTKKA Failure of flow detection valve for 1st clutch TM E03 system
DDTLKA Failure of flow detection valve for 2nd clutch TM E03 Electrical
DDTMKA Failure of flow detection valve for 3rd clutch TM E03 Part 5
system
SEN01112-00
DDTNKA Failure of flow detection valve for R clutch TM E03 Electrical
system
Electrical
DF10KA No lever signal input TM E03 system
Electrical
DF10KB Multiple lever signal input TM E03 system
Electrical
DGF1KX T/M oil temperature out of range TM E03 system
DGR2KZ Ground fault of brake oil temperature sensor (rear) MON E01 Electrical
system system
DGR2L8 Disconnection of brake oil temperature sensor (rear) MON E01 Electrical
system system
DGR3KZ Ground fault of brake oil temperature sensor (center) MON E01 Electrical
system system
Disconnection of brake oil temperature sensor (cen- Electrical
DGR3L8 ter) system MON E01 system
Ground fault of brake oil temperature sensor (front) Electrical
DGR4KZ system MON E01 system
Disconnection of brake oil temperature sensor (front) Electrical
DGR4L8 system MON E01 system
DGR6KX Steering oil temperature signal out of range TM E01 Electrical
system
DGT1KX Short circuit of T/C oil temperature sensor system TM E01 Electrical
system
Disconnection, ground fault, and short circuit of T/C Electrical
DHT5KX fluid TM E01 system
pressure sensor system
Electrical
DHT5L6 T/C fluid pressure sensor failure TM E01 system Troubleshooting
Accumulator fluid pressure sensor (front) system Electrical by failure code,
DHU2KX failure BK E01 system Part 6
SEN01113-00
Accumulator fluid pressure sensor (rear) system fail- Electrical
DHU3KX ure BK E01 system
DJF1KA Disconnection of fuel level sensor system MON E01 Electrical
system
DK51L5 Manual retarder potentiometer and RVS failure BK E03 Electrical
system
6 HM400-2

DK52KX Dump lever potentiometer failure 1 TM E03 Electrical
system
Electrical
DK53L8 Dump lever potentiometer failure 2 TM E03 system
Electrical
DK54KX Body positioner sensor failure TM E03 system
Electrical
DKH0KX Pitch angle sensor signal out of range TM E01 system
DLF1KA Disconnection of T/M input shaft speed sensor sys- TM E03 Electrical
tem system
DLF1LC T/M input shaft speed sensor failure TM E03 Electrical
system
DLF2KA Disconnection of T/M intermediate shaft speed sen- TM E03 Electrical
sor system system
Electrical
DLF2LC T/M intermediate shaft speed sensor failure TM E03 system
Disconnection of T/M differential speed sensor sys- Electrical
DLF4KA tem TM E01 system
Disconnection of T/M output shaft speed sensor sys- Electrical
DLT3KA tem TM E03 system
Electrical
DV00KB Short circuit of buzzer output MON E01 system
DW72KZ Kick out solenoid output system failure (disconnec- TM E01 Electrical
tion or ground fault) system
DW73KZ Dump selector valve output system failure TM E03 Electrical
DW78KZ Rear wheel BCV command output system failure BK E01 Part 6
system
SEN01113-00
Electrical
DW79KZ Front wheel BCV command output system failure BK E01 system
Rear wheels electromagnetic proportional pressure Electrical
DX11K4 reducing valve failure 1 BK E03 system
Disconnection of rear wheels electromagnetic pro-
DX11KA portional BK E03 Electrical
pressure reducing valve output system system
Ground fault of rear wheels electromagnetic propor- Electrical
DX11KB tional BK E03 system
DX11KY Hot short of rear wheels electromagnetic propor- BK E03 Electrical
tional pressure reducing valve output circuit system
DX11MA Rear wheels electromagnetic proportional pressure BK E03 Electrical
reducing valve failure 2 system
Front wheels electromagnetic proportional pressure Electrical
DX12K4 reducing valve failure 1 BK E03 system
Disconnection of rear wheels electromagnetic pro-
DX12KA portional BK E03 Electrical
pressure reducing valve output circuit system
Ground fault of front wheels electromagnetic propor-
DX12KB tional BK E03 Electrical
pressure reducing valve output circuit system
DX12KY Hot short circuit of front wheels electromagnetic pro- BK E03 Electrical
portional pressure reducing valve output circuit system
DX12MA Front wheels electromagnetic proportional pressure BK E03 Electrical
reducing valve failure 2 system
DX13KA Disconnection of Dump EPC valve output circuit TM E03 Electrical
system
DX13KB Ground fault of Dump EPC valve output circuit TM E03 system by failure code,
Electrical Part 7
DX13KY Hot short circuit of Dump EPC valve output circuit TM E03 system SEN01114-00
Rear wheels differential lock-up command output Electrical
DX14KZ system failure BK E03 system
HM400-2 7

DX15KZ Front wheels differential lock-up command output BK E03 Electrical
system failure system
Disconnection of inter axle differential lock-up clutch Electrical
DXH0KA solenoid output circuit TM E01 system
Ground fault of inter axle differential lock-up clutch Electrical
DXH0KB solenoid output circuit TM E01 system
Hot short circuit of inter axle differential lock-up Electrical
DXH0KY clutch solenoid output circuit TM E03 system
DXH1KA Disconnection of L/U clutch solenoid output circuit TM E03 Electrical
system
DXH1KB Ground fault of lock-up clutch solenoid output circuit TM E03 Electrical
system
DXH1KY Hot short circuit of lock-up clutch solenoid output cir- TM E03 Electrical
cuit system
DXH2KA Disconnection of Hi clutch solenoid output circuit TM E03 system by failure code,
Electrical Part 7
DXH2KB Ground fault of Hi clutch solenoid output circuit TM E03 system SEN01114-00
Electrical
DXH2KY Hot short circuit of Hi clutch solenoid output circuit TM E03 system
Electrical
DXH3KA Disconnection of Lo clutch solenoid output circuit TM E03 system
DXH3KB Ground fault of Lo clutch solenoid output circuit TM E03 Electrical
system
DXH3KY Hot short circuit of Lo clutch solenoid output circuit TM E03 Electrical
system
DXH4KA Disconnection of 1st clutch solenoid output circuit TM E03 Electrical
system
Electrical
DXH4KB Ground fault of 1st clutch solenoid output circuit TM E03 system
Electrical
DXH4KY Hot short circuit of 1st clutch solenoid output circuit TM E03 system
Electrical
DXH5KA Disconnection of 2nd clutch solenoid output circuit TM E03 system
DXH5KB Ground fault of 2nd clutch solenoid output circuit TM E03 Electrical
system
DXH5KY Hot short circuit of 2nd clutch solenoid output circuit TM E03 Electrical
system
DXH6KA Disconnection of 3rd clutch solenoid output circuit TM E03 Electrical
DXH6KB Ground fault of 3rd clutch solenoid output circuit TM E03 system Part 8
DXH6KY Hot short circuit of 3rd clutch solenoid output circuit TM E03 system
Electrical
DXH7KA Disconnection of R clutch solenoid output circuit TM E03 system
DXH7KB Ground fault of R clutch solenoid output circuit TM E03 Electrical
system
DXH7KY Hot short circuit of R clutch solenoid output circuit TM E03 Electrical
system
8 HM400-2
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
BK : Retarder controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
HM400-2 9
Before troubleshooting by failure code 1

a This connection table shows the devices to which each power supply of the circuit breakers and fuse box
supplies power (An accessory power supply is a device which supplies power while the starting switch is
in the ON position and an unswitched power supply is a device which supplies power while the starting
switch is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Locations and connections of circuit breakers (30 A and 80 A)
Circuit breaker Circuit breaker

Type of power supply Destination of power
No. capacity
Fuse box (BT2)
Unswitched power 1 30A
Fuse box (BT4)
supply
2 30A Fuse box (BT3)
Fuse box (BT1)
Accessory power
Fuse box (BT2)
supply 4 80A
Fuse box (BT3)
Fuse box (BT4)
10 HM400-2
Location and connection of fuse box (BT1)
Type of power supply Fuse No. Fuse capacity Destination of power

Lamp switch circuit (including brightness control switch)
BT1-No. 3 power supply (through relay)
1 20A BT1-No. 4 power supply (through relay)
BT1-No. 5 power supply (through switch)
2 10A Flasher
3 20A Headlamp (High beam)
Accessory power
4 10A Headlamp (Low beam)
supply
5 10A Small lamp (Right)
6 10A Small lamp (Left)
7 10A Stop lamp (Right and left)
Backup lamp (Right and left)
8 20A
Backup buzzer
9 20A Front working lamp (Right and left)
10 20A Service power supply connector
HM400-2 11

11 10A Engine controller (Starting switch ACC signal)
12 10A KOMTRAX terminal
13 10A Machine monitor
Accessory power
14 10A Parking brake solenoid valve
supply
15 10A Rear view monitor
16 20A Front wiper motor
17 20A Rear wiper motor
Machine monitor
18 10A
KOMTRAX
19 10A Retarder controller
20 20A Starting switch (Terminal B power supply)
Unswitched power 21 10A Transmission controller
supply 22 20A Hazard lamp (Front, rear, right, and left)
23 10A Emergency steering relay (motor circuit) and timer
Room lamp
24 10A
Car radio or car stereo
12 HM400-2

26 20A Fog lamp (Right and left)
27 20A Air conditioner unit
28 10A Heater
29 10A Heater
Machine monitor
30 10A
Alarm buzzer
Accessory power Transmission controller
32 10A
supply Shift lever
33 10A Emergency steering relay (signal circuit) and timer
34 20A Power window motor (Right)
35 20A Power window motor (Left)
36 — (Spare)
37 — (Spare)
38 — (Spare)
39 30A Rear glass heater
Unswitched power
40 30A Engine controller
supply
HM400-2 13

41 10A Room lamp 2
42 10A Car radio or car stereo
Accessory power
43 10A Yellow rotary lamp
supply
44 20A Side lamp (Right and left)
45 10A Intake air heater relay
Unswitched power
46 10A Horn (Right and left)
supply
47 10A Tachograph
Accessory power 48 10A Cigarette lighter
supply 49 10A Air suspension seat
14 HM400-2
Location and connection of fuse (V)

Accessory power
V 300A Intake air heater
supply
HM400-2 15
Fuse box (BT4)

41 10A Room lamp 2
Accessory power
supply
Unswitched power
supply
47 10A Tachograph
16 HM400-2
Information in troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on Trouble Trouble name displayed in fault history of machine monitor
Display on machine
machine moni-
monitor
tor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of
Action taken by machine monitor or controller to protect system or devices when they detect
machine moni-
trouble
tor or controller
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do not
(1) Method of indicating connector No. and handling of T-
indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
18 HM400-2
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• "Connector No. and pin No." from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
• Arrow (i o): Roughly shows the location on the machine.
HM400-2 19

© 2006 KOMATSU
All Rights Reserved
20 HM400-2
SEN01108-00
HM400-2

HM400-2 2001 and up
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 1 .......................................................................................................... 3
Failure code [1500L0] Double engagement ......................................................................................... 3
Failure code [15B0NX] Transmission oil filter: Clogged ....................................................................... 4
Failure code [15F0KM] R o F shifting abuse 1.................................................................................... 6
Failure code [15F0MB] R o F shifting abuse 2.................................................................................... 6
Failure code [15F7KM] Transmission forward clutch abuse ............................................................... 7
Failure code [15G0MW] Trouble in reverse clutch system (Slip) ......................................................... 8
Failure code [15G7KM] Transmission reverse clutch abuse.............................................................. 10
Failure code [15H0MW] Trouble in Hi clutch system (Slip) ................................................................ 12
Failure code [15J0MW] Trouble in Lo clutch system (Slip) ............................................................... 14
Failure code [15K0MW] Trouble in 1st clutch system (Slip)............................................................... 16
Failure code [15L0MW] Trouble in 2nd clutch system (Slip) .............................................................. 18
Failure code [15M0MW] Trouble in 3rd clutch system (Slip).............................................................. 20
Failure code [15SBL1] Trouble in reverse clutch pressure control valve ........................................ 22
Failure code [15SBMA] Trouble in reverse clutch pressure control valve ..................................... 26
Failure code [15SCL1] Trouble in Hi clutch pressure control valve ................................................. 28
HM400-2 1
Failure code [15SCMA] Trouble in Hi clutch pressure control valve .............................................. 32

Failure code [15SDL1] Trouble in Lo clutch pressure control valve ............................................... 34
Failure code [15SDMA] Trouble in Lo clutch pressure control valve ............................................. 36
1
2 HM400-2
Troubleshooting by failure code, Part 1 1

Failure code [1500L0] Double engagement 1
Action code Failure code Double engagement
Trouble
E03 1500L0 (Transmission controller system)
Contents of
• Fill switch signals of 2 clutches of wrong combination were inputted.
trouble
Action of • Turns transmission cut-off relay OFF.
controller • Sets gear speed in neutral.
Problem that
appears on • Gear speed is set in neutral suddenly during travel and machine cannot restart.
machine
Related
• Method of reproducing failure code: Start engine + Travel.
information

Clutch ECMV solenoid valve may be defective. Carry out trouble-
Defective clutch ECMV sole- shooting for other displayed failure code(s).
1
noid valve (Internal defect) • Failure codes that can be displayed together with this code:
Possible causes [15SBL1], [15SCL1], [15SDL1], [15SEL1], [15SFL1], [15SGL1]
and standard
value in normal Defective hydraulic and
Clutch ECMV solenoid valve may be defective. Carry out trouble-
state 2 mechanical systems of
shooting for hydraulic and mechanical systems.
clutch ECMV solenoid valve
If causes 1 – 2 are not detected, transmission controller may be
Defective transmission con-
3 defective. (Since trouble is in system, troubleshooting cannot be
troller
carried out.)
HM400-2 3
Failure code [15B0NX] Transmission oil filter: Clogged 1

Action code Failure code Transmission oil filter: Clogged
Trouble
E01 15B0NX (Transmission controller system)
Contents of • When torque converter oil temperature is above 50°C, signal circuit of transmission oil filter clogging
trouble switch is open (disconnected from ground).
Action of
• None in particular.
controller
Problem that
appears on • If machine is used as it is, transmission may be broken.
machine
• After taking remedy and checking that system is repaired, initialize transmission controller, referring
Related
to Testing and adjusting, Setting and adjusting each device.
information
• Method of reproducing failure code: Start engine.

Clogged transmission oil fil-
1 Transmission oil filter may be clogged. Clean or replace it.
ter (When system is normal)
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
T03 (male) Transmission oil filter Resistance
When normal
(Reference: Differen-
Defective transmission oil fil- tial pressure is below Max. 1 z
2 ter clogging switch (Internal 275 ± 19.6 kPa {2.8 ±
defect) 0.2 kg/cm2})
Between (1) – (2)
When clogged
tial pressure is above Min. 1 Mz
275 ± 19.6 kPa {2.8 ±
0.2 kg/cm2})
Possible causes
and standard
Disconnection in wiring har- ing without turning starting switch ON.
value in normal
state ness (Disconnection in wiring Wiring harness between ATC2 (female) (37) Resis-
3 Max. 1 z
or defective contact in con- – T03 (female) (1) tance
nector) Wiring harness between T03 (female) (2) – Resis-
Max. 1 z
ground T1 tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
ATC2 (female) Transmission oil filter Voltage
When normal
Defective transmission con- tial pressure is below Max. 1 V
4 275 ± 19.6 kPa {2.8 ±
troller
Between (37) – chas- 0.2 kg/cm })
2
sis ground When clogged

tial pressure is above 20 – 30 V
275 ± 19.6 kPa {2.8 ±
0.2 kg/cm2})
4 HM400-2
Circuit diagram related to transmission oil filter clogging switch
HM400-2 5
Failure code [15F0KM] R o F shifting abuse 1 1

Action code Failure code R o F shifting abuse 1
Trouble
— 15F0KM (Transmission controller system)
Contents of • Shifting from reverse to forward was detected 10 times in total while output shaft speed was 200 -
trouble 300 rpm (approx. 4 – 6 km/h).
Action of
controller
Problem that
appears on • If machine is used as it is, it may be broken.
machine
Related • Output shaft speed can be checked with monitoring function.
information (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: OUT - 31400)

Gearshift lever may have been operated wrongly (Transmission
Possible causes Wrong operation of gearshift may have been set in forward during reverse travel). Teach opera-
1
and standard lever tor correct operation. (Travel direction must be changed after
value in normal machine is stopped completely.)
state If cause 1 is not detected, transmission controller may be defec-
2 tive. (Since trouble is in system, troubleshooting cannot be carried
troller
out.)
Failure code [15F0MB] R o F shifting abuse 2 1

Action code Failure code R o F shifting abuse 2
Trouble
— 15F0MB (Transmission controller system)
Contents of • Shifting from reverse to forward was detected 5 times in total while output shaft speed was above
trouble 300 rpm (approx. 6 km/h).
Action of
controller
Problem that
machine
Related • Output shaft speed can be checked with monitoring function.
information (Monitoring code: TRANSMISSION - TRANSMISSION SPEED: OUT - 31400)

Possible causes Wrong operation of gearshift may have been set in forward during reverse travel). Teach opera-
1
and standard lever tor correct operation. (Travel direction must be changed after
value in normal machine is stopped completely.)
troller
out.)
6 HM400-2
Failure code [15F7KM] Transmission forward clutch abuse 1

Action code Failure code Transmission forward clutch abuse
Trouble
— 15F7KM (Transmission controller system)
Contents of • Shifting from neutral or reverse to forward was detected 10 times in total while engine speed was
trouble above 1,800 rpm.
Action of
controller
Problem that
machine
Related
information

Possible causes Wrong operation of gearshift may have been set in forward while engine was running higher
1
and standard lever than set speed). Teach operator correct operation. (Transmission
value in normal must be set to forward while engine is running at low idle.)
troller
out.)
HM400-2 7
Failure code [15G0MW] Trouble in reverse clutch system (Slip) 1

Action code Failure code Trouble in reverse clutch system (Slip)
Trouble
E03 15G0MW (Transmission controller system)
• When signal is output to reverse clutch ECMV solenoid valve, value calculated from signals of
Contents of
transmission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse
trouble
speed sensor is abnormal.
Action of • Shifts up and keeps gear speed according to gear speed before trouble and "Table 1".
controller • Turns lockup system OFF.
Problem that
appears on • Machine cannot travel in reverse.
machine
• Output current to reverse clutch ECMV solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV R DIR - 31606)
information
• Method of reproducing failure code: Start engine + Travel at R1

Defective reverse clutch ing without turning starting switch ON.
1 ECMV solenoid valve (Inter-
CN8 (male) Resistance
nal defect)
Between (1) – (2) 5 – 15 z
Possible causes ness (Disconnection in wiring Wiring harness between ATC3 (female) (13) Resis-
and standard 2 Max. 1 z
or defective contact in con- – CN8 (female) (2) tance
value in normal nector)
state Wiring harness between ATC3 (female) (25) Resis-
Max. 1 z
– CN8 (female) (1) tance
troller
carried out.)
Defective hydraulic and If causes 1 – 3 are not detected, reverse clutch or reverse clutch
mechanical systems of ECMV solenoid valve may have trouble in its hydraulic and
4
reverse clutch or reverse mechanical systems. Carry out troubleshooting for hydraulic and
clutch ECMV solenoid valve mechanical systems.
8 HM400-2
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
Circuit diagram related to reverse clutch ECMV solenoid valve
HM400-2 9
Failure code [15G7KM] Transmission reverse clutch abuse 1

Action code Failure code Transmission reverse clutch abuse
Trouble
— 15G7KM (Transmission controller system)
Contents of • Shifting from neutral or forward to reverse was detected 10 times in total while engine speed was
trouble above 1,800 rpm.
Action of
controller
Problem that
machine
Related
information

Possible causes Wrong operation of gearshift may have been set in reverse while engine was running higher
1
and standard lever than set speed). Teach operator correct operation. (Transmission
value in normal must be set to reverse while engine is running at low idle.)
troller
out.)
10 HM400-2
Failure code [15H0MW] Trouble in Hi clutch system (Slip) 1

Action code Failure code Trouble in Hi clutch system (Slip)
Trouble
E03 15H0MW (Transmission controller system)
• When signal is output to Hi clutch ECMV solenoid valve, value calculated from signals of transmis-
Contents of
sion input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed
trouble
sensor is abnormal.
Problem that
appears on • Machine travels at gear speeds which do not use Hi clutch.
machine
• Output current to Hi clutch ECMV solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV H DIR - 31600)
information
• Method of reproducing failure code: Start engine + Travel at F2.

Defective Hi clutch ECMV ing without turning starting switch ON.
1 solenoid valve (Internal
defect)
Between (1) – (2) 5 – 15 z
Max. 1 z
troller
carried out.)
Defective hydraulic and If causes 1 – 3 are not detected, Hi clutch or Hi clutch ECMV sole-
mechanical systems of Hi noid valve may have trouble in its hydraulic and mechanical sys-
4
clutch or Hi clutch ECMV tems. Carry out troubleshooting for hydraulic and mechanical
solenoid valve systems.
12 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
Circuit diagram related to Hi clutch ECMV solenoid valve
HM400-2 13
Failure code [15J0MW] Trouble in Lo clutch system (Slip) 1

Action code Failure code Trouble in Lo clutch system (Slip)
Trouble
E03 15J0MW (Transmission controller system)
• When signal is output to Lo clutch ECMV solenoid valve, value calculated from signals of transmis-
Contents of
trouble
sensor is abnormal.
Problem that
appears on • Machine travels at gear speeds which do not use Lo clutch.
machine
• Output current to Lo clutch ECMV solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV L DIR - 31601)
information
• & Method of reproducing failure code: Start engine + Travel at F1.

Defective Lo clutch ECMV CN6 (male) Resistance
defect) Between (1) – (2) 5 – 15 z
Between (1), (2) – chassis
Min. 1 Mz
ground
Possible causes ing without turning starting switch ON.
Disconnection in wiring har-
and standard
ness (Disconnection in wiring Wiring harness between ATC3 (female) (3) Resis-
value in normal 2 Max. 1 z
state
nector) Wiring harness between ATC3 (female) (6) Resis-
Max. 1 z
troller
carried out.)
Defective hydraulic and If causes 1 – 3 are not detected, Lo clutch or Lo clutch ECMV sole-
mechanical systems of Lo noid valve may have trouble in its hydraulic and mechanical sys-
4
clutch or Lo clutch ECMV tems. Carry out troubleshooting for hydraulic and mechanical
14 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
Circuit diagram related to Lo clutch ECMV solenoid valve
HM400-2 15
Failure code [15K0MW] Trouble in 1st clutch system (Slip) 1

Action code Failure code Trouble in 1st clutch system (Slip)
Trouble
E03 15K0MW (Transmission controller system)
• When signal is output to 1st clutch ECMV solenoid valve, value calculated from signals of transmis-
Contents of
trouble
sensor is abnormal.
Problem that
• If gearshift lever is set in neutral, machine cannot start. (For emergency escape method, see Test-
appears on
ing and adjusting, "Emergency escape method when electrical system has trouble".)
machine
• Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602)
information

Defective 1st clutch ECMV CN12 (male) Resistance
Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
Defective hydraulic and If causes 1 – 3 are not detected, 1st clutch or 1st clutch ECMV
mechanical systems of 1st solenoid valve may have trouble in its hydraulic and mechanical
4
clutch or 1st clutch ECMV systems. Carry out troubleshooting for hydraulic and mechanical
16 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
Circuit diagram related to 1st clutch ECMV solenoid valve
HM400-2 17
Failure code [15L0MW] Trouble in 2nd clutch system (Slip) 1

Action code Failure code Trouble in 2nd clutch system (Slip)
Trouble
E03 15L0MW (Transmission controller system)
• When signal is output to 2nd clutch ECMV solenoid valve, value calculated from signals of trans-
Contents of
mission input shaft speed sensor, intermediate shaft speed sensor, and output shaft reverse speed
trouble
sensor is abnormal.
Problem that
appears on
machine
• Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function.
Related
information

Defective 2nd clutch ECMV ing without turning starting switch ON.
defect)
Between (1) – (2) 5 – 15 z
Max. 1 z
troller
carried out.)
Defective hydraulic and If causes 1 – 3 are not detected, 2nd clutch or 2nd clutch ECMV
mechanical systems of 2nd solenoid valve may have trouble in its hydraulic and mechanical
4
clutch or 2nd clutch ECMV systems. Carry out troubleshooting for hydraulic and mechanical
18 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
Circuit diagram related to 2nd clutch ECMV solenoid valve
HM400-2 19
Failure code [15M0MW] Trouble in 3rd clutch system (Slip) 1

Action code Failure code Trouble in 3rd clutch system (Slip)
Trouble
E03 15M0MW (Transmission controller system)
• When signal is output to 3rd clutch ECMV solenoid valve, value calculated from signals of transmis-
Contents of
trouble
sensor is abnormal.
Problem that
appears on
machine
• Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function.
Related
information

Defective 3rd clutch ECMV ing without turning starting switch ON.
defect)
Between (1) – (2) 5 – 15 z
Max. 1 z
troller
carried out.)
Defective hydraulic and If causes 1 – 3 are not detected, 3rd clutch or 3rd clutch ECMV
mechanical systems of 3rd solenoid valve may have trouble in its hydraulic and mechanical
4
clutch or 3rd clutch ECMV systems. Carry out troubleshooting for hydraulic and mechanical
20 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
Circuit diagram related to 3rd clutch ECMV solenoid valve
HM400-2 21
Failure code [15SBL1] Trouble in reverse clutch pressure control valve 1

Action code Failure code Trouble in reverse clutch pressure control valve
Trouble
E03 15SBL1 (Transmission controller system)
Contents of
• When signal to reverse clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON.
trouble
Problem that
appears on • Machine cannot travel forward.
machine
• Input signal to reverse clutch ECMV fill switch can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - D-IN--8-----15 - 40906)
information
• When machine is checked for cause 1, its travel speed at R1 gear speed reaches about 7 km/h.
Take care of safety around machine extremely.

a Prepare with starting switch OFF, then start engine and carry
out troubleshooting.
Defective reverse clutch
1 ECMV fill switch (Internal CN9 (male) Gear speed Resistance
defect) Between (1) – chas- N Min. 1 Mz
sis ground R1 Max. 1 z
Possible causes a Prepare with starting switch OFF, then carry out troubleshoot-
Ground fault in wiring har- ing without turning starting switch ON.
and standard
2 ness (Short circuit with GND
value in normal Wiring harness between ATC3 (female) (29) Resis-
circuit) Min. 1 Mz
state – CN9 (female) (1) tance
troller
carried out.)
4
22 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 23
Circuit diagram related to reverse clutch ECMV fill switch
24 HM400-2
Failure code [15SBMA] Trouble in reverse clutch pressure control valve 1

Action code Failure code Trouble in reverse clutch pressure control valve
Trouble
E03 15SBMA (Transmission controller system)
Contents of • When signal is output to reverse clutch ECMV solenoid valve, signal from fill switch is kept OFF and
trouble clutch is not engaged.
Problem that
appears on • Machine cannot travel in reverse.
machine
Related
information
• Method of reproducing failure code: Start engine + Travel at R1.

Defective reverse clutch CN8 (male) Resistance
nal defect) Between (1) – (2) 5 – 15 z
Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
4
26 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 27
Failure code [15SCL1] Trouble in Hi clutch pressure control valve 1

Action code Failure code Trouble in Hi clutch pressure control valve
Trouble
E03 15SCL1 (Transmission controller system)
Contents of
• When signal to Hi clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON.
trouble
Problem that
• Machine travels at gear speeds which use Hi clutch.
appears on
• Machine cannot travel in reverse.
machine
• Input signal to Hi clutch ECMV fill switch can be checked with monitoring function.
Related
information
• When machine is checked for cause 1, its travel speed at F2 gear speed reaches about 11 km/h.

a Prepare with starting switch OFF, then start engine with gear-
shift lever at position 2 and gear speed at F2 and carry out
troubleshooting.
Defective Hi clutch ECMV fill
1 CN11 (male) Gear speed Resistance
switch (Internal defect)
Between (1) – chas- N Min. 1 Mz
sis ground F2 Max. 1 z
and standard Ground fault in wiring har- ing without turning starting switch ON.
value in normal 2 ness (Short circuit with GND
state circuit) Wiring harness between ATC3 (female) (30) Resis-
Min. 1 Mz
troller
carried out.)
4
28 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 29
Circuit diagram related to Hi clutch ECMV fill switch
30 HM400-2
Failure code [15SCMA] Trouble in Hi clutch pressure control valve 1

Action code Failure code Trouble in Hi clutch pressure control valve
Trouble
E03 15SCMA (Transmission controller system)
Contents of • When signal is output to Hi clutch ECMV solenoid valve, signal from fill switch is kept OFF and
Problem that
appears on • Machine travels at gear speeds which do not use Hi clutch.
machine
Related
information

Defective Hi clutch ECMV CN10 (male) Resistance
Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
4
32 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 33
Failure code [15SDL1] Trouble in Lo clutch pressure control valve 1

Action code Failure code Trouble in Lo clutch pressure control valve
Trouble
E03 15SDL1 (Transmission controller system)
Contents of
• When signal to Lo clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON.
trouble
Problem that
• Machine travels at gear speeds which do not use Lo clutch.
appears on
machine
• Input signal to Lo clutch ECMV fill switch can be checked with monitoring function.
Related
information

Defective Lo clutch ECMV fill CN7 (male) Gear speed Resistance
1
and standard
circuit) Min. 1 Mz
troller
carried out.)
4
34 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
Circuit diagram related to Lo clutch ECMV fill switch
HM400-2 35
Failure code [15SDMA] Trouble in Lo clutch pressure control valve 1

Action code Failure code Trouble in Lo clutch pressure control valve
Trouble
E03 15SDMA (Transmission controller system)
Contents of • When signal is output to Lo clutch ECMV solenoid valve, signal from fill switch is kept OFF and
Problem that
• Gear speed is set in neutral suddenly during travel.
appears on
• Once machine stops, it can restart.
machine
Related
information

Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
4
36 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 37
38 HM400-2

© 2006 KOMATSU
All Rights Reserved
40 HM400-2
SEN01109-02
HM400-2

HM400-2 2001 and up
Failure code [15SEL1] Trouble in 1st clutch pressure control valve ............................................................. 3
Failure code [15SEMA] Trouble in 1st clutch pressure control valve .......................................................... 6
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve ............................................................ 8
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve ....................................................... 12
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve .......................................................... 14
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve ........................................................ 18
Failure code [15SJMA] Trouble in lockup clutch pressure control valve ................................................... 20
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve ....................... 22
Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 ............................... 24
Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1............................... 26
Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 ................................ 28
Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1 ............................... 30
Failure code [2C4MNX] Clogging of retarder cooling oil filter ....................................................................... 32
Failure code [2F00KM] Dragging of parking brake ....................................................................................... 34
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) ........................................................... 36
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear)............................................................ 36
HM400-2 1
Failure code [989A00] Operation of engine overrun prevention system ....................................................... 37

Failure code [989D00] Rear section tipping over alarm (Raising operation on slope) .................................. 37
Failure code [A570NX] Clogging of engine oil filter....................................................................................... 38
Failure code [AA10NX] Clogging of air cleaner............................................................................................. 40
Failure code [AB00MA] Trouble in battery charge circuit .............................................................................. 42
Failure code [B@BAZG] Lowering of engine oil pressure............................................................................. 43
Failure code [B@BAZK] Lowering of engine oil level.................................................................................... 44
Failure code [B@BCNS] Overheating of engine ........................................................................................... 45
Failure code [B@BCZK] Lowering of coolant level ....................................................................................... 46
Failure code [B@BFZK] Lowering of fuel level ............................................................................................. 48
Failure code [B@C6NS] Overheating of brake cooling oil (front).................................................................. 49
Failure code [B@C7NS] Overheating of brake cooling oil (rear) .................................................................. 49
Failure code [B@C8NS] Overheating of brake cooling oil (center)............................................................... 50
Failure code [B@CENS] Overheating of torque converter oil ....................................................................... 50
Failure code [B@JANS] Overheating of steering oil ..................................................................................... 51
2 HM400-2
Failure code [15SEL1] Trouble in 1st clutch pressure control valve 1

Action code Failure code Trouble in 1st clutch pressure control valve
Trouble
E03 15SEL1 (Transmission controller system)
Contents of
• When signal to 1st clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON.
trouble
Problem that
appears on • Machine travels at gear speeds which use 1st clutch.
machine
• Input signal to 1st clutch ECMV fill switch can be checked with monitoring function.
Related
information

Defective 1st clutch ECMV CN13 (male) Gear speed Resistance
1
fill switch (Internal defect)
and standard
circuit) Min. 1 Mz
troller
carried out.)
4
HM400-2 3
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
4 HM400-2
Circuit diagram related to 1st clutch ECMV fill switch
HM400-2 5
Failure code [15SEMA] Trouble in 1st clutch pressure control valve 1

Action code Failure code Trouble in 1st clutch pressure control valve
Trouble
E03 15SEMA (Transmission controller system)
Contents of • When signal is output to 1st clutch ECMV solenoid valve, signal from fill switch is kept OFF and
Problem that
appears on • Machine travels at gear speeds which do not use 1st clutch.
machine
Related
information

Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
4
6 HM400-2
Table 1
Gear speed
before trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 7
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve 1

Action code Failure code Trouble in 2nd clutch pressure control valve
Trouble
E03 15SFL1 (Transmission controller system)
Contents of
• When signal to 2nd clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON.
trouble
Problem that
appears on • Machine travels at gear speeds which use 2nd clutch.
machine
• Input signal to 2nd clutch ECMV fill switch can be checked with monitoring function.
Related
information

Defective 2nd clutch ECMV CN15 (male) Gear speed Resistance
1
and standard
circuit) Min. 1 Mz
troller
carried out.)
4
8 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 9
Circuit diagram related to 2nd clutch ECMV fill switch
10 HM400-2
HM400-2 11
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve 1

Action code Failure code Trouble in 2nd clutch pressure control valve
Trouble
E03 15SFMA (Transmission controller system)
Contents of • When signal is output to 2nd clutch ECMV solenoid valve, signal from fill switch is kept OFF and
Problem that
appears on • Machine travels at gear speeds which do not use 2nd clutch.
machine
Related
information

Defective 2nd clutch ECMV CN14 (male) Resistance
Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
4
12 HM400-2
Table 1
Gear speed
before trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 13
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve 1

Action code Failure code Trouble in 3rd clutch pressure control valve
Trouble
E03 15SGL1 (Transmission controller system)
Contents of
• When signal to 3rd clutch ECMV solenoid valve is turned OFF, signal from fill switch is kept ON.
trouble
Problem that
appears on • Machine travels at gear speeds which use 3rd clutch.
machine
• Input signal to 3rd clutch ECMV fill switch can be checked with monitoring function.
Related
information

Defective 3rd clutch ECMV CN17 (male) Gear speed Resistance
1
and standard
circuit) Min. 1 Mz
troller
carried out.)
4
14 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 15
Circuit diagram related to 3rd clutch ECMV fill switch
16 HM400-2
HM400-2 17
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve 1

Action code Failure code Trouble in 3rd clutch pressure control valve
Trouble
E03 15SGMA (Transmission controller system)
Contents of • When signal is output to 3rd clutch ECMV solenoid valve, signal from fill switch is kept OFF and
Problem that
appears on • Machine travels at gear speeds which do not use 3rd clutch.
machine
Related
information

Defective 3rd clutch ECMV CN16 (male) Resistance
Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
4
18 HM400-2
Table 1
Gear speed
before trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 19
Failure code [15SJMA] Trouble in lockup clutch pressure control valve 1

Action code Failure code Trouble in lockup clutch pressure control valve
Trouble
E03 15SJMA (Transmission controller system)
Contents of • When signal is output to lockup clutch ECMV solenoid valve, signal from fill switch is kept OFF and
Action of • Keeps current gear speed and turns lockup system OFF.
controller • Keeps gear speed at neutral after gearshift lever is set to "N".
Problem that
• Lockup system is reset and gear speed cannot be changed.
appears on
• If gearshift lever is set to "N", machine cannot restart until it stops.
machine
• Output current to lockup clutch solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV LU DIR - 31609)
information
• Method of reproducing failure code: Start engine + Travel at F1 + Turn lockup pilot lamp.

Defective lockup clutch sole- CN18 (male) Resistance
1
noid valve (Internal defect) Between (1) – (2) 5 – 15 z
Min. 1 Mz
ground
and standard
state
Max. 1 z
troller
carried out.)
Defective hydraulic and If causes 1 – 3 are not detected, lockup clutch or lockup clutch
4
lockup clutch or lockup clutch mechanical systems. Carry out troubleshooting for hydraulic and
ECMV solenoid valve mechanical systems.
20 HM400-2
Circuit diagram related to lockup clutch ECMV fill switch
HM400-2 21
Failure code [15SKMA] Trouble in interaxle differential lock clutch

pressure control valve 1
Action code Failure code Trouble in interaxle differential lock clutch pressure control valve
Trouble
E01 15SKMA (Transmission controller system)
Contents of • When signal is output to interaxle differential lock clutch solenoid valve, signal from fill switch is kept
trouble OFF and clutch is not engaged.
Action of
• Turns interaxle differential lock command OFF.
controller
Problem that
appears on • Interaxle differential lock does not operate.
machine
• Output current to interaxle differential lock clutch solenoid valve can be checked with monitoring
function.
(Monitoring code: TRANSMISSION - ECMV D DIR - 31607)
Related
• Slip of clutch can be checked by displaying following simultaneously with monitoring function.
information
(Monitoring code: TRANSMISSION - TRANSMISSION SPEED: OUT - 31400)
(Monitoring code: TRANSMISSION - TRANSMISSION DIFF OUT - 31402)
• Method of reproducing failure code: Turn starting switch ON + Operate interaxle switch (manual).

Defective interaxle differen- CN20 (male) Resistance
1 tial lock clutch solenoid valve
(Internal defect) Between (1) – (2) 5 – 15 z
Min. 1 Mz
ground
Possible causes Disconnection in wiring har- ing without turning starting switch ON.
and standard ness (Disconnection in wiring Wiring harness between ATC3 (female) (23) Resis-
2 Max. 1 z
value in normal or defective contact in con- – CN20 (female) (2) tance
state nector) Wiring harness between ATC3 (female) (35) Resis-
Max. 1 z
troller
carried out.)
Defective hydraulic and
If causes 1 – 3 are not detected, interaxle differential lock clutch or
mechanical systems of inter-
interaxle differential lock clutch solenoid may have trouble in its
4 axle differential lock clutch or
hydraulic and mechanical systems. Carry out troubleshooting for
interaxle differential lock
hydraulic and mechanical systems.
clutch solenoid
22 HM400-2
Circuit diagram related to interaxle differential lock clutch ECMV fill switch
HM400-2 23
Failure code [2A62L1] Trouble in front wheel differential lock pressure

control valve 2 1
Action code Failure code Trouble in front wheel differential lock pressure control valve 2
Trouble
E01 2A62L1 (Retarder controller system)
Contents of • When signal to front differential lock clutch solenoid valve circuit is turned OFF, signal from differen-
trouble tial lock oil pressure switch (front) is kept ON.
Action of
controller
Problem that
appears on • There is no particular effect on machine.
machine
Related • Method of reproducing failure code: Turn starting switch ON + Set right and left differential lock
information switches to neutral position.

a Prepare with starting switch OFF, then start engine, press right
and left differential lock pedals, and carry out troubleshooting.
Defective differential lock oil Right and left differ-
1 pressure switch (front) (Inter- B39 (male) Resistance
ential lock switches
nal defect)
Upper position Min. 1 Mz
Between (1) – (2)
Lower position Max. 1 z
and standard
value in normal Wiring harness between BRC3 (female) Resis-
circuit) Min. 1 Mz
state (10) – chassis ground tance
If causes 1 – 2 are not detected, retarder controller may be defec-
3 Defective retarder controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
If causes 1 – 3 are not detected, front differential lock clutch or
mechanical systems of front
front differential lock clutch solenoid valve may have trouble in its
4 differential lock clutch or front
differential lock clutch sole-
noid valve
24 HM400-2
Circuit diagram related to differential lock oil pressure switch (front)
HM400-2 25
Failure code [2A62LH] Trouble in front wheel differential lock pressure

control valve 1 1
Action code Failure code Trouble in front wheel differential lock pressure control valve 1
Trouble
E01 2A62LH (Retarder controller system)
Contents of • When signal is output to front differential lock solenoid circuit 30 seconds or more after engine is
trouble started, signal from differential lock oil pressure switch (front) is kept OFF.
Action of
controller
Problem that
machine
information switches to lower position + Press right and left differential lock pedals.

a Prepare with starting switch OFF, then start engine, press right
and left differential lock pedals, and carry out troubleshooting.
Defective differential lock oil Right and left differ-
1 pressure switch (front) (Inter- B39 (male) Resistance
nal defect)
Upper position Min. 1 Mz
Between (1) – (2)
Lower position Max. 1 z
and standard ness (Disconnection in wiring Wiring harness between BRC3 (female) Resis-
2 Max. 1 z
value in normal or defective contact in con- (10) – B39 (female) (1) tance
state nector) Wiring harness between B39 (female) (2) – Resis-
Min. 1 Mz
chassis ground (ER) tance
out.)
If causes 1 – 3 are not detected, front differential lock clutch or
mechanical systems of front
front differential lock clutch solenoid valve may have trouble in its
4 differential lock clutch or front
differential lock clutch sole-
noid valve
Note: This troubleshooting code is not applied to the fol-
lowing serial number # 2038 – 2452.
26 HM400-2
Circuit diagram related to differential lock oil pressure switch (front)
HM400-2 27
Failure code [2B62L1] Trouble in rear wheel differential lock pressure

control valve 2 1
Action code Failure code Trouble in rear wheel differential lock pressure control valve 2
Trouble
E01 2B62L1 (Retarder controller system)
Contents of • When signal to rear differential lock clutch solenoid valve circuit is turned OFF, signal from differen-
trouble tial lock oil pressure switch (center) (rear) is kept ON.
Action of • None in particular.
controller
Problem that
machine
information switches to upper or lower position + Press right and left differential lock pedals

Right and left differ-
B40 (male) ential lock switches Resistance
and differential lock
pedals
Defective differential lock oil ential lock switches:
1 pressure switch (center) Neutral position
Right and left differ- Min. 1 Mz
(Internal defect)
ential lock pedals:
Released
Between (1) – (2)
ential lock switches:
Upper position Max. 1 z
ential lock pedals:
Pressed
B41 (male) and differential lock Resistance
Possible causes pedals
and standard
value in normal Right and left differ-
state Defective differential lock oil ential lock switches:
2 pressure switch (rear) (Inter- Neutral position Min. 1 Mz
nal defect) Right and left differ-
ential lock pedals:
Released
Between (1) – (2)
ential lock pedals:
Pressed
Ground fault in wiring har-
3 ness (Short circuit with GND Wiring harness between BRC3 (female) Resis- Min. 1 Mz
circuit) (20) – chassis ground ER tance
Wiring harness between B40 (female) (2) – Resis- Min. 1 Mz
chassis ground ER tance
out.)
Defective hydraulic and If causes 1 – 4 are not detected, rear differential lock clutch or rear
mechanical systems of rear differential lock clutch solenoid may have trouble in its hydraulic
5 differential lock clutch or rear and mechanical systems. Carry out troubleshooting for hydraulic
differential lock clutch sole- and mechanical systems.
noid
28 HM400-2
Circuit diagram related to differential lock oil pressure switches (center and rear)
HM400-2 29
Failure code [2B62LH] Trouble in rear wheel differential lock pressure

control valve 1 1
Action code Failure code Trouble in rear wheel differential lock pressure control valve 1
Trouble
E01 2B62LH (Retarder controller system)
Contents of • When signal is output to rear differential lock solenoid circuit 30 seconds or more after engine is
trouble started, signal from differential lock oil pressure switch is kept OFF.
Action of • None in particular.
controller
Problem that
machine
information switches to upper or lower position + Press right and left differential lock pedals

B40 (male) ential lock switches Resistance
and differential lock
pedals
1 pressure switch (center) Neutral position Min. 1 Mz
(Internal defect) Right and left differ-
ential lock pedals:
Released
Between (1) – (2)
ential lock pedals:
Pressed
Possible causes B41 (male) ential lock switches Resistance
and standard and differential lock
value in normal pedals
state Right and left differ-
2 pressure switch (rear) (Inter- Neutral position Min. 1 Mz
nal defect) Right and left differ-
ential lock pedals:
Released
Between (1) – (2)
ential lock pedals:
Pressed
3 ness (Disconnection in wiring Wiring harness between BRC3 (female) Resis- Max. 1 z
or defective contact in con- (20) – B40 (1) (female) tance
nector)
Wiring harness between BRC3 (female) Resis- Min. 1 Mz
(21), (31), (32), (33) – B41 (2) (female) tance
out.)
5 Defective hydraulic and If causes 1 – 4 are not detected, carry out troubleshooting for
mechanical systems hydraulic and mechanical systems.
Note:This troubleshooting code is not applied to the following serial number # 2038 – 2452.
30 HM400-2
Circuit diagram related to differential lock oil pressure switches (center and rear)
HM400-2 31
Failure code [2C4MNX] Clogging of retarder cooling oil filter 1

Action code Failure code Clogging of retarder cooling oil filter
Trouble
E01 2C4MNX (Machine monitor system)
Contents of • When brake oil temperature is above 50°C while engine is running, signal circuit of retarder oil filter
trouble clogging switch is open (disconnected from chassis ground).
Action of
machine monitor
Problem that
appears on • If machine is used as it is, foreign matter may be sent to retarder cooling circuit.
machine
Related • This failure code is used for only machines having retarder oil filter clogging switches.
information • Method of reproducing failure code: Start engine.

Clogged retarder oil filter
1 Check filter. If it is clogged, clean or replace.
(When system is normal)
M08 (male) Retarder oil filter Resistance
When normal
Defective retarder oil filter tial pressure is below Max. 1 z
2 clogging switch (Internal 98.1 ± 19.6 kPa
defect) {1.0 ± 0.2 kg/cm2})
Between (1) – (2)
When clogged
98.1 ± 19.6 kPa
{1.0 ± 0.2 kg/cm2})
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between DPC2B (female) Resis-
3 Max. 1 z
or defective contact in con- (6) – M08 (female) (2) tance
nector) Wiring harness between DPC2B (female) Resis-
Max. 1 z
(7) – M08 (female) (1) tance
DPC2B Retarder oil filter Voltage
When normal
tial pressure is below Max. 1 V
4 Defective machine monitor 98.1 ± 19.6 kPa
{1.0 ± 0.2 kg/cm2})
Between (6) – (7)
When clogged
98.1 ± 19.6 kPa
{1.0 ± 0.2 kg/cm2})
32 HM400-2
Circuit diagram related to retarder oil filter clogging switch
HM400-2 33
Failure code [2F00KM] Dragging of parking brake 1

Action code Failure code Dragging of parking brake
Trouble
– 2F00KM (Transmission controller system)
Contents of
• While signal circuit of parking brake was ON, operator performed travel operation.
trouble
Action of
controller
Problem that
appears on • If machine is used as it is, parking brake may be damaged.
machine
Related
information

Wrong operation of parking Parking brake switch may have been operated wrongly. Teach
1 brake switch (When system operator correct operation. (Travel must be started after parking
is normal) brake switch is turned OFF.)
2 Defective fuse (BT3-No. 33) If fuse is broken, circuit probably has ground fault. (See cause 6.)
Defective parking brake relay
3 Replace parking brake relay (R02) with another relay and perform
(R02) (Internal defect)
reproducing operation. If blinking failure code lights up at this time,
relay is defective.
Defective parking brake oil Parking brake oil
4 pressure switch (Internal B17 (male) Resistance
pressure switch
defect)
ON Max. 1 z
Between (1) – (2)
Possible causes OFF Min. 1 Mz
and standard
value in normal
state
Disconnection in wiring har- Wiring harness between R02 (female) (2), Resis-
Max. 1 z
ness (Disconnection in wiring (6) – chassis ground tance
5
or defective contact in con- Wiring harness between fuse BT3-No. 33 Resis-
nector) Max. 1 z
(16) – B17 (female) (1) tance
Wiring harness between R02 (female) (1) – Resis-
Max. 1 z
B17 (female) (2) tance
circuit) Wiring harness between BRC3 (female) (9) Resis-
Max. 1 z
– R02 (female) (3) tance
Defective transmission con- BRC3 Parking brake switch Voltage
7
troller
Between (9) – chas- Parking 20 – 30 V
sis ground Travel Max. 1 V
34 HM400-2
Circuit diagram related to parking brake switch
HM400-2 35
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) 1

Action code Failure code Lowering of accumulator oil pressure (front)
Trouble
E03 2G42ZG (Retarder controller system)
Contents of • While engine is running, signal of accumulator oil pressure sensor (front) lowered below 6.86 MPa
trouble {70 kg/cm2}.
Action of
controller
Problem that
appears on • If machine is used as it is, front brake may not work.
machine
• Front accumulator pressure can be checked with monitoring function.
Related
(Monitoring code: BRAKE - ACC OIL PRE F - 35500)
information

Possible causes Lowering of front accumula-
Oil pressure in front accumulator may be lowered. Check and
and standard 1 tor oil pressure (When sys-
repair.
value in normal tem is normal)
state If cause 1 is not detected, retarder controller may be defective.
2 Defective retarder controller
(Since trouble is in system, troubleshooting cannot be carried out.)
Failure code [2G43ZG] Lowering of accumulator oil pressure (rear) 1

Action code Failure code Lowering of accumulator oil pressure (rear)
Trouble
E03 2G43ZG (Retarder controller system)
Contents of • While engine is running, signal of accumulator oil pressure sensor (rear) lowered below 6.86 MPa
trouble {70 kg/cm2}.
Action of
controller
Problem that
appears on • If machine is used as it is, rear brake may not work.
machine
• Accumulator pressure can be checked with monitoring function.
Related
(Monitoring code: BRAKE - ACC OIL PRE R - 35501)
information

Possible causes Lowering of rear accumulator
Oil pressure in rear accumulator may be lowered. Check and
and standard 1 oil pressure (When system is
repair.
value in normal normal)
state If cause 1 is not detected, retarder controller may be defective.
36 HM400-2
Failure code [989A00] Operation of engine overrun prevention system 1

Action code Failure code Operation of engine overrun prevention system
Trouble
E02 989A00 (Machine monitor system)
Contents of
• While gear speed is not neutral, transmission input shaft speed is above 2,450 rpm.
trouble
Action of
• Outputs command signal to retarder controller to operate brake (retarder).
machine monitor
Problem that
appears on • Brake (Retarder) operates to lower travel speed.
machine
• Input shaft speed can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - TRANSMISSION SPEED:IN - 31200)
information
• Overrun signal is received from transmission controller through network.

Overrun of engine (When Engine may have overrun. Teach operator correct operation.
1
system is normal) (Engine speed must be kept below 2,450 rpm.)
Possible causes
and standard If cause 1 is not detected, transmission controller may be defec-
value in normal 2 tive. (Since trouble is in system, troubleshooting cannot be carried
troller
state out.)
out.)
Failure code [989D00] Rear section tipping over alarm (Raising operation
on slope) 1
Action code Failure code Rear section tipping over alarm (Raising operation on slope)
Trouble
– 989D00 (Machine monitor system)
Contents of
• While machine is slanting more than 15°, dump body is raised.
trouble
Action of
• Turns pitch angle caution lamp ON and sounds alarm buzzer.
machine monitor
Problem that
appears on • If dump body is raised as it is, machine may tip over.
machine
• Pitch angle and pitch angle signal can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - ANGLE SENSOR - 32900)
information • Information of operation of rear section tipping over alarm is received from transmission controller
through network.

Dump body may have been raised on slope sharper than 15°.
Wrong dumping operation
1 Teach operator correct operation. (Dump body must not be raised
Possible causes on slope sharper than 15°.)
and standard If cause 1 is not detected, transmission controller may be defec-
value in normal Defective transmission con-
state troller
out.)
out.)
HM400-2 37
Failure code [A570NX] Clogging of engine oil filter 1

Action code Failure code Clogging of engine oil filter
Trouble
E01 A570NX (Transmission controller system)
Contents of
• While engine is running, engine oil filter clogging signal is detected.
trouble
Action of
controller
Problem that
appears on • If machine is used as it is, engine may be damaged.
machine
• Operation of engine oil filter clogging switch can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - D-IN-24-----31 - 40908)
information

Clogged engine oil filter Engine oil filter may be clogged. Check it, then replace if neces-
1
(When system is normal) sary.
0F (male) Engine oil filter Resistance
When normal
Defective engine oil filter tial pressure is below Max. 1 z
2 clogging switch (Internal 147.1 – 186.3 kPa
defect) Between 0F – chas- {1.5 – 1.9 kg/cm2})
147.1 – 186.3 kPa
Possible causes {1.5 – 1.9 kg/cm2})
and standard
value in normal Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
state ness (Disconnection in wiring ing without turning starting switch ON.
3
or defective contact in con- Wiring harness between ATC2 (female) (3) Resis-
nector) Max. 1 z
– 0F (male) tance
ATC2 (female) Engine oil filter Voltage
When normal
Defective transmission con- tial pressure is below Max. 1 V
4 147.1 – 186.3 kPa
troller
Between (3) – chas- {1.5 – 1.9 kg/cm2})
147.1 – 186.3 kPa
{1.5 – 1.9 kg/cm2})
38 HM400-2
Circuit diagram related to engine oil filter clogging switch
HM400-2 39
Failure code [AA10NX] Clogging of air cleaner 1

Action code Failure code Clogging of air cleaner
Trouble
E01 AA10NX (Machine monitor system)
Contents of • While engine is running, air cleaner clogging signal circuit is kept open (disconnected from chassis
trouble ground) for 2 seconds.
Action of
machine monitor
Problem that
appears on • If machine is used as it is, engine output may be lowered.
machine
Related
information

Clogged air cleaner (When Air cleaner may be clogged. Check it, then clean or replace if nec-
1
system is normal) essary.
Defective air cleaner clog- out troubleshooting.
3
ging sensor (Internal defect) M11 (male) Voltage
Between (1) – (2) 20 – 30 V
Replace dust indicator relay (R03) with another relay and perform
reproducing operation. If blinking failure code lights up at this time,
Defective dust indicator relay relay is defective.
4
(R03) (Internal defect) a Prepare with starting switch OFF, then check relay unit.
R03 (male) Resistance
Possible causes Between (1) – (2) 200 – 400 z
and standard Between (3) – (6) Max. 1 z
value in normal
state Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
ness (Disconnection in wiring ing without turning starting switch ON.
5
or defective contact in con- Wiring harness between DPC2B (female) Resis-
nector) Max. 1 z
(2) – DPC2B (female) (6) tance
6 ness (Short circuit with GND Min. 1 Mz
DPC2B (female) (2) tance
circuit)
Wiring harness between DPC2B (female) Resis-
Min. 1 Mz
a Check monitoring code: 40902 "MONITOR PANEL D-IN-18"
with real-time function.
7 Defective machine monitor
DPC2B Voltage Real-time display
20 – 30 V 0
(2) – (6)
Max. 1 V 1
40 HM400-2
Circuit diagram related to air cleaner clogging sensor
HM400-2 41
Failure code [AB00MA] Trouble in battery charge circuit 1

Action code Failure code Trouble in battery charge circuit
Trouble
E03 AB00MA (Transmission controller system)
Contents of
• While engine is running, generation signal is not input from alternator.
trouble
Action of
• Turns battery charge circuit caution lamp ON and sounds alarm buzzer.
controller
Problem that
appears on • If machine is used as it is, battery voltage lowers and machine may not able to continue travel.
machine
• Battery voltage can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ALTERNATOR R - 04301)
information

a Prepare with starting switch OFF, then run engine (at medium
Defective charge by alterna- speed) and carry out troubleshooting.
1
tor (When system is normal) R, E Engine speed Voltage
Between R – E Medium or higher 27.6 – 29.5 V
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
and standard ness (Disconnection in wiring ing without turning starting switch ON.
value in normal 2
or defective contact in con- Wiring harness between ATC1 (female) Resis-
state nector) Max. 1 z
alternator R tance
a Prepare with starting switch OFF, then run engine (at medium
speed) and carry out troubleshooting.
3 ATC1 Engine speed Voltage
troller
Between (15) – chas-
Medium or higher 27.6 – 29.5 V
sis ground
Circuit diagram related to battery charge circuit
42 HM400-2
Failure code [B@BAZG] Lowering of engine oil pressure 1

Action code Failure code Lowering of engine oil pressure
Trouble
– B@BAZG (Engine controller system)
Contents of • While engine was running, engine oil pressure sensor signal circuit detected abnormal lowering of
trouble engine oil pressure.
Action of • Operates with normal control system.
controller • Turns engine oil pressure caution lamp ON and sounds alarm buzzer.
Problem that
appears on • If machine is used as it is, engine may be seized.
machine
• Engine oil pressure can be checked with monitoring function.
Related
(Monitoring code: ENGINE - ENGINE OIL PRESS - 37200)
information

Lowering of engine oil pres-
Possible causes Engine oil pressure may be low. Check it and remove cause, if
1 sure (When system is nor-
and standard necessary.
mal)
value in normal
state If cause 1 is not detected, engine oil pressure sensor system may
Defective engine oil pressure
2 be defective. Carry out troubleshooting for failure codes [CA135]
sensor system
and [CA141].
HM400-2 43
Failure code [B@BAZK] Lowering of engine oil level 1

Action code Failure code Lowering of engine oil level
Trouble
E01 B@BAZK (Transmission controller system)
Contents of
• Engine oil level switch signal circuit is open (disconnected from chassis ground).
trouble
Action of
• Operates with normal control system.
controller
Problem that
appears on • If machine is used as it is, engine may be seized.
machine
• Operation of engine oil level switch can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - D-IN-24-----31 - 40908)
information
• Method of reproducing failure code: Turn starting switch ON.

Check engine oil level and add new oil if necessary.
Lowering of engine oil level
1 a If engine oil level is low, check around engine for oil leakage
before adding oil.
Defective engine oil level 0L (male) Engine oil level Resistance
2
Possible causes Between (1) – chas- Between H – L levels Max. 1 z
and standard sis ground L level Min. 1 Mz
value in normal
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
ness (Disconnection in wiring
3
nector) Max. 1 z
– 0L (female) (1) tance
Defective transmission con- ATC2 Engine oil level Voltage
4
troller
Between (13) – chas- Between H – L levels Max. 1 V
sis ground L level 20 – 30 V
Circuit diagram related to engine oil level switch
44 HM400-2
Failure code [B@BCNS] Overheating of engine 1

Action code Failure code Overheating of engine
Trouble
E02 B@BCNS (Engine controller system)
Contents of • While engine was running, engine coolant temperature sensor signal circuit detected overheating of
trouble engine coolant.
Action of • Limits fuel injection until coolant temperature lowers to operating range.
controller • Turns engine oil pressure caution lamp ON and sounds alarm buzzer.
Problem that
appears on • Engine output lowers.
machine
Related • Engine coolant temperature can be checked with monitoring function.
information (Monitoring code: ENGINE - COOLANT TEMP - 04104)

Possible causes Overheating of engine cool- Engine coolant may be overheating. Check it and remove cause, if
1
and standard ant (When system is normal) necessary.
value in normal If cause 1 is not detected, engine coolant temperature gauge sys-
state Defective engine coolant
2 tem may be defective. Carry out troubleshooting for failure codes
temperature gauge system
[CA144] and [CA145].
Circuit diagram related to engine coolant temperature sensor
HM400-2 45
Failure code [B@BCZK] Lowering of coolant level 1

Action code Failure code Lowering of coolant level
Trouble
E01 B@BCZK (Machine monitor system)
Contents of • Signal circuit of radiator coolant level switch is kept open (disconnected from chassis ground) for 30
trouble seconds.
Action of
machine monitor
Problem that
appears on • If machine is used as it is, engine may overheat.
machine
• Operation of radiator coolant level switch can be checked with monitoring function.
Related
(Monitoring code: MONITOR PANEL - D-IN-16-----23 - 40902)
information

Lowering of radiator coolant
Coolant level in radiator sub tank may be low. Check it and add
1 level (When system is nor-
coolant if necessary.
mal)
Defective radiator coolant Radiator coolant
2 M01 (male) Resistance
level switch (Internal defect) level
Normal Max. 1 z
Between (1) – (2)
Low Min. 1 Mz
and standard ness (Disconnection in wiring Wiring harness between DPC2B (female) Resis-
state nector) Wiring harness between DPC2B (female) Resis-
Max. 1 z
If causes 1 – 3 are not detected, machine monitor may be defec-
4 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
a Check monitoring code: 40902 "MONITOR PANEL D-IN-22"
with real-time function.
DPC2B Voltage Real-time display
20 – 30 V 0
(4) – (6)
Max. 1 V 1
46 HM400-2
Circuit diagram related to radiator coolant level switch
HM400-2 47
Failure code [B@BFZK] Lowering of fuel level 1

Action code Failure code Lowering of fuel level
Trouble
– B@BFZK (Machine monitor system)
Contents of
• Fuel level sensor signal indicates lowering of fuel level (Resistance of 70 z or higher is detected).
trouble
Action of • Does not display this failure code, if DJF1KA is detected.
machine monitor • Turns fuel level caution lamp ON.
Problem that
appears on • None in particular.
machine
• When fuel level is below LOW and fuel is added, if failure code disappears, fuel was insufficient.
Related • Signal from fuel level sensor can be checked with monitoring function.
information (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200/04201)

Lack of fuel (When system is
1 Fuel may be insufficient. Check and add fuel, if necessary.
normal)
Defective fuel level sensor M06 (male) Fuel level Resistance

2 (Internal disconnection or When full Approx. 10 z
short circuit) Between (1) – (2)
When empty Approx. 80 z
and standard Disconnection in wiring har-
value in normal ness (Disconnection in wiring Wiring harness between DPC3B (female) Resis-
3 Max. 1 z
state or defective contact in con- (3) – M06 (female) (1) tance
nector) Wiring harness between DPC3B (female) Resis-
Max. 1 z
4 Defective machine monitor DPC3B (female) Fuel level Resistance
When full Approx. 10 z
Between (3) – (6)
When empty Approx. 80 z
Circuit diagram related to fuel level sensor
48 HM400-2
Failure code [B@C6NS] Overheating of brake cooling oil (front) 1

Action code Failure code Overheating of brake cooling oil (front)
Trouble
E02 B@C6NS (Machine monitor system)
Contents of
• Front brake cooling oil is overheating.
trouble
Action of
• Turns retarder oil temperature caution lamp ON and sounds alarm buzzer.
machine monitor
Problem that
appears on • If machine is used as it is, front brake may be broken.
machine
• Brake oil temperature can be checked with monitoring function.
Related
(Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30201)
information
(Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30204)

Overheating of front brake
Possible causes Front brake cooling oil may be overheating. Check for cause and
1 cooling oil (When system is
and standard repair.
normal)
value in normal
state If cause 1 is not detected, brake oil temperature sensor (front) sys-
Defective brake oil tempera-
2 tem may be defective. Carry out troubleshooting for failure code
ture sensor (front) system
[DGR4KZ].
Failure code [B@C7NS] Overheating of brake cooling oil (rear) 1

Action code Failure code Overheating of brake cooling oil (rear)
Trouble
Contents of
• Rear brake cooling oil is overheating.
trouble
Action of
machine monitor
Problem that
appears on • If machine is used as it is, rear brake may be broken.
machine
Related
(Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30202)
information
(Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30205)

Overheating of rear brake
Possible causes Rear brake cooling oil may be overheating. Check for cause and
normal)
value in normal
state If cause 1 is not detected, brake oil temperature sensor (rear) sys-
2 tem may be defective. Carry out troubleshooting for failure code
ture sensor (rear) system
[DGR2KZ].
HM400-2 49
Failure code [B@C8NS] Overheating of brake cooling oil (center) 1

Action code Failure code Overheating of brake cooling oil (center)
Trouble
Contents of
• Center brake cooling oil is overheating.
trouble
Action of
machine monitor
Problem that
appears on • If machine is used as it is, center brake may be broken.
machine
Related
(Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30203)
information
(Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30206)

Overheating of center brake
Possible causes Center brake cooling oil may be overheating. Check for cause and
normal)
value in normal
state If cause 1 is not detected, brake oil temperature sensor (center)
2 system may be defective. Carry out troubleshooting for failure
ture sensor (center) system
code [DGR3KZ].
Failure code [B@CENS] Overheating of torque converter oil 1

Action code Failure code Overheating of torque converter oil
Trouble
E02 B@CENS (Machine monitor system)
Contents of
• Torque converter oil is overheating.
trouble
Action of
• Turns torque converter oil temperature caution lamp ON and sounds alarm buzzer.
machine monitor
Problem that
appears on • If machine is used as it is, torque converter may be broken.
machine
• Signal of torque converter oil temperature sensor is input to transmission controller and then its
Related information is transmitted to machine monitor through communication system.
information • Power train oil temperature can be checked with monitoring function.
(Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100)

Overheating of torque con-
Possible causes Torque converter oil may be overheating. Check for cause and
1 verter oil (When system is
normal)
value in normal
state Defective torque converter If cause 1 is not detected, torque converter oil temperature sensor
2 oil temperature sensor sys- system may be defective. Carry out troubleshooting for failure
tem code [DGT1KX].
50 HM400-2
Failure code [B@JANS] Overheating of steering oil 1

Action code Failure code Overheating of steering oil
Trouble
E02 B@JANS (Machine monitor system)
Contents of
• Signal circuit of steering oil temperature switch is open (disconnected from chassis ground).
trouble
Action of
• Turns steering oil temperature caution lamp ON and sounds alarm buzzer.
machine monitor
Problem that
appears on • If machine is used as it is, oil may leak.
machine
Related • Steering oil temperature can be checked with monitoring function.
information (Monitoring code: TRANSMISSION - STRG OIL TEMP - 32701)

Possible causes Overheating of steering oil
1 Steering oil may be overheating. Check for cause and repair.
and standard (When system is normal)
value in normal If cause 1 is not detected, steering oil temperature sensor system
state Defective steering oil tem-
2 may be defective. Carry out troubleshooting for failure code
perature sensor system
[DGR6KX].
HM400-2 51

© 2009 KOMATSU
All Rights Reserved
52 HM400-2
SEN01110-02
HM400-2

HM400-2 2001 and up
Failure code [CA111] Trouble in engine controller .......................................................................................... 4
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors............................................................ 6
Failure code [CA122] Abnormally high charge pressure ................................................................................ 8
Failure code [CA123] Abnormally low charge pressure................................................................................ 10
Failure code [CA131] Abnormally high throttle sensor signal ....................................................................... 12
Failure code [CA132] Abnormally low throttle sensor signal......................................................................... 14
Failure code [CA135] Abnormally high engine oil pressure .......................................................................... 16
Failure code [CA141] Abnormally low engine oil pressure ........................................................................... 18
Failure code [CA144] Abnormally high coolant temperature ........................................................................ 20
Failure code [CA145] Abnormally low coolant temperature.......................................................................... 22
Failure code [CA153] Abnormally high charge temperature ......................................................................... 24
Failure code [CA154] Abnormally low charge temperature .......................................................................... 26
Failure code [CA187] Abnormally low voltage in sensor power supply 2 ..................................................... 27
Failure code [CA221] Abnormally high ambient pressure............................................................................. 28
Failure code [CA222] Abnormally low ambient pressure .............................................................................. 30
Failure code [CA227] Abnormally high voltage in sensor power supply 2 .................................................... 32
HM400-2 1
Failure code [CA234] Engine overspeed ...................................................................................................... 34

Failure code [CA238] Trouble in Ne speed sensor power supply ................................................................. 36
Failure code [CA263] Abnormally high fuel temperature .............................................................................. 38
Failure code [CA265] Abnormally low fuel temperature................................................................................ 40
Failure code [CA271] Short circuit in PCV1 .................................................................................................. 41
Failure code [CA272] Disconnection in PCV1............................................................................................... 42
Failure code [CA273] Short circuit in PCV2 .................................................................................................. 43
Failure code [CA274] Disconnection in PCV2............................................................................................... 44
Failure code [CA322] Disconnection or short circuit in injector #1 (L #1) ..................................................... 46
Failure code [CA342] Matching error in engine controller data..................................................................... 58
Failure code [CA351] Trouble in injector drive circuit.................................................................................... 60
Failure code [CA352] Abnormally low voltage in sensor power supply 1...................................................... 62
Failure code [CA386] Abnormally high voltage in sensor power supply 1 .................................................... 64
2 HM400-2
HM400-2 3
Failure code [CA111] Trouble in engine controller 1

Action code Failure code Trouble in engine controller
Trouble
E03 CA111 (Engine controller system)
Contents of
• Engine controller has trouble in it.
trouble
Action of
controller
Problem that
appears on • Machine continues operation normally but may stop suddenly or may not able to restart.
machine
Related • Source voltage of engine controller can be checked with monitoring function.
information (Monitoring code: ENGINE - POWER SUPPLY - 03200)

If circuit breaker has tripped, circuit probably has ground fault.
1 Trip of circuit breaker (30 A)
(See cause 4.)
Wiring harness between J3P (female) (3), Resis-
Max. 1 z
(4) – fuse BT3-No. 40 (30) tance
Wiring harness between fuse BT3-No. 40 Resis-
Max. 1 z
Disconnection in wiring har- (29) – circuit breaker 83 terminal tance
ness (Disconnection in wiring Wiring harness between circuit breaker 81 Resis-
3 Max. 1 z
or defective contact in con- terminal – circuit breaker 82 terminal tance
nector) Wiring harness between circuit breaker 82 Resis-
Max. 1 z
terminal – battery relay 66 terminal tance
Wiring harness between battery relay 66 – Resis-
Max. 1 z
battery (+) terminal tance
Possible causes Max. 1 z
(2) – chassis ground GS tance
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
Max. 1 z
Max. 1 z
(29) – circuit breaker 83 terminal tance
Wiring harness between circuit breaker 81 Resis-
4 ness (Short circuit with GND Max. 1 z
terminal – circuit breaker 82 terminal tance
circuit)
Max. 1 z
Max. 1 z
Max. 1 z
5 Defective engine controller J3P Starting switch Voltage
Between (3), (4) –
ON 20 – 30 V
(1), (2)
4 HM400-2
Circuit diagram related to engine controller power supply
HM400-2 5
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors 1

Action code Failure code Trouble in engine Ne and Bkup speed sensors
Trouble
Contents of
• Both engine Ne and Bkup speed sensor circuits have troubles in them.
trouble
Action of
controller
Problem that
• Engine cannot be started (if it has been stopped).
appears on
• Engine stops (if it has been running).
machine
Related
information

Defective Ne speed sensor Ne speed sensor system may be defective. Carry out trouble-
1
system shooting for failure code [CA689].
Defective Bkup speed sen- Bkup speed sensor system may be defective. Carry out trouble-
2
sor system shooting for failure code [CA778].
Defective installation of Ne Installation of Ne speed sensor may be defective. Check it directly
Possible causes 3
speed sensor (for defective installation, internal defect of flywheel, etc.)
and standard
value in normal Installation of Bkup speed sensor may be defective. Check it
Defective installation of Bkup
state 4 directly (for defective installation, internal defect of supply pump,
speed sensor
etc.)
Defective connection of sen- Ne speed sensor and Bkup speed sensor may be connected
5
sor (Wrong connection) defectively (wrongly). Check them directly.
If causes 1 – 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
6 HM400-2
HM400-2 7
Failure code [CA122] Abnormally high charge pressure 1

Action code Failure code Abnormally high charge pressure
Trouble
Contents of
• Charge pressure sensor circuit detected abnormally high pressure.
trouble
Action of
controller • Fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation.
Problem that
• Acceleration performance of engine lowers.
appears on
• More black smoke is produced during acceleration.
machine
Related
information

Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
ply system shooting for it first.
or start engine and carry out troubleshooting.
PIM Voltage
Defective charge pressure
2 Between (1) – (2) Power supply 4.75 – 5.25 V
sensor (Internal defect)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
Max. 1 z
ness (Disconnection in wiring – PIM (female) (1) tance
3
or defective contact in con- Wiring harness between ENG (female) (47) Resis-
nector) Max. 1 z
– PIM (female) (2) tance
Wiring harness between ENG (female) (44) Resis-
Max. 1 z
Possible causes
and standard
value in normal Wiring harness between ENG (female) (37) Resis-
Ground fault in wiring har- Min. 1 Mz
state – PIM (female) (1) tance
circuit) Wiring harness between ENG (female) (47) Resis-
Min. 1 Mz
Min. 1 Mz
Wiring harness between ENG (female) (37)
Resis-
– PIM (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – PIM (female) (2)
5 ness (with another wiring Wiring harness between ENG (female) (37)
harness) Resis-
tance
(female) (44) – PIM (female) (3)
Resis-
tance
(female) (44) – PIM (female) (3)
6 Defective engine controller
ENG Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
8 HM400-2
Circuit diagram related to charge pressure sensor
HM400-2 9
Failure code [CA123] Abnormally low charge pressure 1

Action code Failure code Abnormally low charge pressure
Trouble
Contents of
• Charge pressure sensor circuit detected abnormally low pressure.
trouble
Action of
• Fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation.
controller
Problem that
• Acceleration performance of engine lowers.
appears on
• More black smoke is produced during acceleration.
machine
Related • Condition of charge pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - CHG PRESS-A - 36500/36501)
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
10 HM400-2
HM400-2 11
Failure code [CA131] Abnormally high throttle sensor signal 1

Action code Failure code Abnormally high throttle sensor signal
Trouble
Contents of
• Signal voltage of throttle sensor is above 4.5 V.
trouble
• Throttle is set to low idle while pedal is released and set to medium speed while pedal is pressed
Action of
according to idle validation switch
controller
• Turns caution lamp ON and sounds alarm buzzer.
Problem that
appears on • When accelerator pedal is pressed, engine speed does not rise above medium.
machine
Related
information

Defective sensor power sup- If failure code [CA2185] or [CA2186] is displayed, carry out trou-
1
ply system bleshooting for it first.
AS1 Accelerator pedal Voltage
All range
Defective accelerator pedal Between (1) – (3) 4.75 – 5.25 V
2 (Power supply)
(Internal defect)
(13 ± 2 % of source
Released
voltage)
Between (2) – (3)
Pressed
voltage)
Disconnection in wiring har- Wiring harness between J2P (female) (22) – Resis-
Max. 1 z
ness (Disconnection in wiring AS1 (female) (1) tance
3
or defective contact in con- Wiring harness between J2P (female) (9) – Resis-
Possible causes nector) Max. 1 z
AS1 (female) (2) tance
and standard
value in normal Wiring harness between J2P (female) (23) – Resis-
Max. 1 z
state AS1 (female) (3) tance
Wiring harness between J2P (female) (22) – Resis-
circuit) Wiring harness between J2P (female) (9) – Resis-
Min. 1 Mz
Min. 1 Mz
J2P Accelerator pedal Voltage
All range
Between (22) – (23) 4.75 – 5.25 V
5 Defective engine controller (Power supply)
Released
voltage)
Between (9) – (23)
Pressed
voltage)
12 HM400-2
Circuit diagram related to accelerator pedal signal

Applied serial number: – 2188
Applied serial number: 2189 and up
HM400-2 13
Failure code [CA132] Abnormally low throttle sensor signal 1

Action code Failure code Abnormally low throttle sensor signal
Trouble
Contents of
• Signal voltage of throttle sensor is abnormally low.
trouble
Action of
• Sets throttle position with signals other than throttle sensor signal and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
14 HM400-2
HM400-2 15
Failure code [CA135] Abnormally high engine oil pressure 1

Action code Failure code Abnormally high engine oil pressure
Trouble
Contents of
• Engine oil pressure sensor circuit detected abnormally high pressure.
trouble
Action of
controller • Fixes engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related • Condition of engine oil pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - ENGINE OIL PRESS - 37201)

1
POIL Voltage
Max. 1 z
ness (Disconnection in wiring – POIL (female) (1) tance
3
nector) Max. 1 z
– POIL (female) (2) tance
Max. 1 z
Possible causes
and standard
value in normal Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
Min. 1 Mz
state ness (Disconnection in wiring – POIL (female) (1) tance
4
nector) Min. 1 Mz
Min. 1 Mz
Resis-
– POIL (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – POIL (female) (2)
harness) Resis-
tance
(female) (13) – POIL (female) (3)
Resis-
tance
(female) (13) – POIL (female) (3)
ENG Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
16 HM400-2
Circuit diagram related to engine oil pressure sensor
HM400-2 17
Failure code [CA141] Abnormally low engine oil pressure 1

Action code Failure code Abnormally low engine oil pressure
Trouble
Contents of
• Engine oil pressure sensor circuit detected abnormally low pressure.
trouble
Action of
• Fixes engine oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related • Condition of engine oil pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - OIL PRESS - 37201)

and standard
state
18 HM400-2
HM400-2 19
Failure code [CA144] Abnormally high coolant temperature 1

Action code Failure code Abnormally high coolant temperature
Trouble
Contents of
• Engine coolant temperature sensor circuit detected abnormally high temperature.
trouble
Action of
• Fixes engine coolant temperature to 90°C and continues operation.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Condition of engine coolant temperature sensor signal can be checked with monitoring function.

Defective engine coolant ing without turning starting switch ON.
1 temperature sensor (Internal
TWTR (male) Coolant temperature Resistance
defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ness (Disconnection in wiring Wiring harness between ENG (female) (15) Resis-
Possible causes 2 Max. 1 z
or defective contact in con- – TWTR (female) (A) tance
and standard nector)
Max. 1 z
state – TWTR (female) (B) tance
Min. 1 Mz
– TWTR (female) (A) tance
ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
20 HM400-2
Circuit diagram related to engine coolant temperature sensor
HM400-2 21
Failure code [CA145] Abnormally low coolant temperature 1

Action code Failure code Abnormally low coolant temperature
Trouble
Contents of
• Engine coolant temperature sensor circuit detected abnormally low temperature.
trouble
Action of
• Fixes engine coolant temperature to 90°C and continues operation.
controller
Problem that
machine
Related • Condition of engine coolant temperature sensor signal can be checked with monitoring function.

and standard
state
22 HM400-2
HM400-2 23
Failure code [CA153] Abnormally high charge temperature 1

Action code Failure code Abnormally high charge temperature
Trouble
Contents of
• Charge temperature sensor circuit detected abnormally high temperature.
trouble
Action of
• Fixes charge temperature (intake air temperature) to 70°C and continues operation.
controller
Problem that
machine
Related • Condition of charge temperature sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - CHG TEMP - 18501)

Defective charge tempera- TIM (male) Charge temperature Resistance
1
ture sensor (Internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) –
All range Min. 1 Mz
chassis ground
Possible causes
or defective contact in con- – TIM (female) (A) tance
value in normal
nector) Wiring harness between ENG (female) (47) Resis-
state Max. 1 z
– TIM (female) (B) tance
Min. 1 Mz
– TIM (female) (A) tance
ENG (female) Charge temperature Resistance
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
24 HM400-2
Circuit diagram related to charge temperature sensor
HM400-2 25
Failure code [CA154] Abnormally low charge temperature 1

Action code Failure code Abnormally low charge temperature
Trouble
Contents of
• Charge temperature sensor circuit detected abnormally low temperature.
trouble
Action of
• Fixes charge temperature (intake air temperature) to 70°C and continues operation.
controller
Problem that
machine
Related • Condition of charge temperature sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - CHG TEMP - 18501)

and standard
state
26 HM400-2
Failure code [CA187] Abnormally low voltage in sensor power supply 21

Action code Failure code Abnormally low voltage in sensor power supply 2
Trouble
Contents of
• Voltage in sensor power supply 2 (5V) circuit of engine controller is abnormally low.
trouble
• Bkup speed sensor operates with Ne speed sensor signal.
• Oil pressure sensor fixes oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues opera-
tion.
• Ambient pressure sensor fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and
Action of continues operation.
controller • Charge pressure sensor fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation.
• EGR inlet pressure sensor fixes EGR inlet pressure to default value (102 kPa {1.05 kg/cm2}) and
limits output and continues operation.
• EGR valve lift sensor limits output and closes EGR valve and bypass valve.
• Bypass valve lift sensor limits output and closes EGR valve and bypass valve.
Problem that
machine
Related
information

and standard
state
HM400-2 27
Failure code [CA221] Abnormally high ambient pressure 1

Action code Failure code Abnormally high ambient pressure
Trouble
Contents of • Ambient pressure sensor circuit detected abnormally high pressure.

trouble
Action of
controller • Fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2} and continues operation.
Problem that
machine
Related • Condition of ambient pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - AMBIENT PRESS - 37401)
1 Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
PAMB Voltage
Defective ambient pressure Between (1) – (2) Power supply 4.75 – 5.25 V
2 sensor (Internal defect)
Between (3) – (2) Signal
– PAMB (female) (1) tance Max. 1 z
ness (Disconnection in wiring
3 or defective contact in con-
nector) – PAMB (female) (2) tance Max. 1 z
Wiring harness between ENG (female) (3) – Resis-

PAMB (female) (3) tance Max. 1 z

and standard
state Ground fault in wiring har- – PAMB (female) (1) tance Min. 1 Mz
– PAMB (female) (2) tance Min. 1 Mz

PAMB (female) (3) tance Min. 1 Mz

– PAMB (female) (1) and between ENG Resis- Min. 1 Mz
(female) (38) – PAMB (female) (2) tance
Short circuit in wiring har-
harness) – PAMB (female) (1) and between ENG Resis- Min. 1 Mz

– PAMB (female) (2) and between ENG Resis- Min. 1 Mz

6 Defective engine controller ENG Voltage

Between (37) – (38) 4.75 – 5.25 V
Between (3) – (38)
28 HM400-2
Circuit diagram related to ambient pressure sensor
HM400-2 29
Failure code [CA222] Abnormally low ambient pressure 1

Action code Failure code Abnormally low ambient pressure
Trouble
Contents of
• Ambient pressure sensor circuit detected abnormally low pressure.
trouble
Action of
• Fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related • Condition of ambient pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - AMBIENT PRESS - 37401)

and standard
state
30 HM400-2
HM400-2 31
Failure code [CA227] Abnormally high voltage in sensor power supply 21

Action code Failure code Abnormally high voltage in sensor power supply 2
Trouble
Contents of • Voltage in sensor power supply 2 (5V) circuit of engine controller is abnormally high.
trouble
• Bkup speed sensor operates with Ne speed sensor signal.
• Oil pressure sensor fixes oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
• Ambient pressure sensor fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and
Action of continues operation.
controller • Charge pressure sensor fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation.
• EGR inlet pressure sensor fixes EGR inlet pressure to default value (102 kPa {1.05 kg/cm2}) and
limits output and continues operation.
• EGR valve lift sensor limits output and closes EGR valve and bypass valve.
• Bypass valve lift sensor limits output and closes EGR valve and bypass valve.
Problem that
machine
Related
information

If another failure code is displayed, carry out troubleshooting for it
1 Defective related system first.
Bkup speed sensor Connector G
Oil pressure sensor Connector POIL
Disconnect devices Ambient pressure
sensor Connector PAMB
at right in order. If
2 Defective sensor (Internal mark E of failure Charge pressure
defect) code disappears Connector PIM
sensor
when a device is dis-
connected, that EGR inlet pressure
device has defect in sensor Connector PEVA
it.
EGR valve lift sensor Connector SEGR
Bypass valve lift
sensor Connector SBP

value in normal ness (Disconnection in wiring Wiring harness between ENG (female) (37) Resis-
state 3 or defective contact in con- – each sensor (female) tance Max. 1 z
nector)
– each sensor (female) tance Max. 1 z

Ground fault in wiring har- Wiring harness between ENG (female) (37) Resis-
4 ness (Short circuit with GND – each sensor (female) tance Min. 1 Mz
circuit)
– each sensor (female) tance Min. 1 Mz

Short circuit in wiring har- ing without turning starting switch ON.
harness) – each sensor (female) and between ENG Resis- Min. 1 Mz
(female) (47) – each sensor (female) tance

6 Defective engine controller ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
32 HM400-2
Circuit diagram related to engine controller sensor power supply (5 V)
HM400-2 33
Failure code [CA234] Engine overspeed 1

Action code Failure code Engine overspeed
Trouble
Contents of
• Engine speed is higher than operating range.
trouble
Action of
• Limits fuel injection until engine speed lowers to operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related • Engine speed can be checked with monitoring function.
information (Monitoring code: ENGINE - ENGINE SPEED - 01002)

1 Defective related system
Possible causes first.
and standard Machine may be used improperly. Teach operator correct opera-
value in normal 2 Improper use
tion.
state
out.)
34 HM400-2
HM400-2 35
Failure code [CA238] Trouble in Ne speed sensor power supply 1

Action code Failure code Trouble in Ne speed sensor power supply
Trouble
Contents of
• Engine Ne speed sensor power supply (5V) has trouble in it.
trouble
Action of
• Controls with signal of engine Bkup speed sensor.
controller
Problem that
• Engine stops it has been running (when Bkup speed sensor also has trouble).
appears on
• Engine cannot be started it has been stopped (when Ne speed sensor also has trouble).
machine
Related
information

When device at right
Defective engine Ne speed is disconnected, if
1
sensor (Internal defect) mark E of failure Engine Ne speed
Connector NE
code disappears, that sensor
device has defect in
it.
2 Max. 1 z
or defective contact in con- – NE (female) (1) tance
– NE (female) (2) tance
and standard
circuit)
Min. 1 Mz
harness) Resis-
– NE (female) (1) and between ENG Min. 1 Mz
tance
(female) (48) – NE (female) (2)
ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
36 HM400-2
Circuit diagram related to engine Ne speed sensor
HM400-2 37
Failure code [CA263] Abnormally high fuel temperature 1

Action code Failure code Abnormally high fuel temperature
Trouble
Contents of
• Fuel temperature sensor circuit detected abnormally high temperature.
trouble
Action of
• Fixes fuel temperature to 90°C and continues operation.
controller
Problem that
appears on
machine
Related • Condition of fuel temperature sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - FUEL TEMP - 04205)

Defective fuel temperature ing without turning starting switch ON.
1
sensor (Internal defect) TFUEL (male) Fuel temperature Resistance
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
or defective contact in con- – TFUEL (female) (A) tance
Max. 1 z
state – TFUEL (female) (B) tance
Min. 1 Mz
– TFUEL (female) (A) tance
ENG (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100°C 0.6 – 20 kz
38 HM400-2
Circuit diagram related to fuel temperature sensor
HM400-2 39
Failure code [CA265] Abnormally low fuel temperature 1

Action code Failure code Abnormally low fuel temperature
Trouble
Contents of
• Fuel temperature sensor circuit detected abnormally low temperature.
trouble
Action of
• Fixes fuel temperature to 90°C and continues operation.
controller
Problem that
appears on
machine
Related • Condition of fuel temperature sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - FUEL TEMP - 04205)

and standard
value in normal Carry out troubleshooting failure code [CA263].
state
40 HM400-2
Failure code [CA271] Short circuit in PCV1 1

Action code Failure code Short circuit in PCV1
Trouble
Contents of
• There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
PCV1 (female) (1) tance
Possible causes circuit)
and standard Min. 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between ENG (female) (4) –
3 Voltage Max. 1 V
24V circuit) in wiring harness PCV1 (female) (1)
Wiring harness between ENG (female) (5) –
Voltage Max. 1 V
PCV1 (female) (2)
EGN (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
Circuit diagram related to supply pump PCV1
HM400-2 41
Failure code [CA272] Disconnection in PCV1 1

Action code Failure code Disconnection in PCV1
Trouble
Contents of
• There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1 PCV1 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between ENG (female) (4) – Resis-
2 Max. 1 z
or defective contact in con- PCV1 (female) (1) tance
Possible causes nector) Wiring harness between ENG (female) (5) – Resis-
and standard Max. 1 z
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
circuit)
Min. 1 Mz
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
42 HM400-2
Failure code [CA273] Short circuit in PCV2 1

Action code Failure code Short circuit in PCV2
Trouble
Contents of
• There is short circuit in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
PCV2 (Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
Possible causes circuit)
and standard Min. 1 Mz
– PCV2 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between ENG (female) (9) –
3 Voltage Max. 1 V
24V circuit) in wiring harness PCV2 (female) (1)
Voltage Max. 1 V
– PCV2 (female) (2)
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
HM400-2 43
Failure code [CA274] Disconnection in PCV2 1

Action code Failure code Disconnection in PCV2
Trouble
Contents of
• There is disconnection in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1 PCV2 (Internal disconnec-
tion) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between ENG (female) (9) – Resis-
2 Max. 1 z
or defective contact in con- PCV2 (female) (1) tance
Possible causes nector) Wiring harness between ENG (female) (10) Resis-
value in normal
circuit)
Min. 1 Mz
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
44 HM400-2
HM400-2 45
Failure code [CA322] Disconnection or short circuit in injector #1 (L #1) 1

Action code Failure code Disconnection or short circuit in injector #1 (L #1)
Trouble
Contents of
• There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
controller
Problem that
• Output is reduced.
appears on
• Rotation is unstable.
machine
Related
information

Defective injector #1 (Inter- CN1 (male) Resistance
1
nal defect) Between (1) – (2) 0.4 – 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
Min. 1 Mz
Defective another cylinder If multiple failure codes are displayed for injector malfunction, carry
4
injector or wiring harness out troubleshooting for them, too.
ENG (female) Resistance
Between (45) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
46 HM400-2
Circuit diagram related to injector #1
HM400-2 47

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
Min. 1 Mz
4
Between (46) – (60) 0.4 – 1.1 z
Min. 1 Mz
ground
48 HM400-2
HM400-2 49

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
Min. 1 Mz
4
Between (55) – (52) 0.4 – 1.1 z
Min. 1 Mz
ground
50 HM400-2
HM400-2 51

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
Min. 1 Mz
4
Between (57) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
52 HM400-2
HM400-2 53

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
Min. 1 Mz
4
Between (54) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
54 HM400-2
HM400-2 55

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
circuit)
Min. 1 Mz
4
Between (56) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
56 HM400-2
HM400-2 57
Failure code [CA342] Matching error in engine controller data 1

Action code Failure code Matching error in engine controller data
Trouble
Contents of
• There is matching error in engine controller.
trouble
Action of
controller
Problem that
appears on • Engine operates normally but may stop or may not be able to restart.
machine
Related
information

and standard
state
58 HM400-2
HM400-2 59
Failure code [CA351] Trouble in injector drive circuit 1

Action code Failure code Trouble in injector drive circuit
Trouble
Contents of
• Injector drive circuit has trouble in it.
trouble
Action of
• Limits engine output and continues operation (Limits common rail pressure).
controller
Problem that
machine

If another failure code (failure code of trouble in injector system) is
displayed, carry out troubleshooting for it first.
(See cause 5.)
Max. 1 z
Max. 1 z
Disconnection in wiring har- (29) – circuit breaker 83 terminal tance
ness (Disconnection in wiring Wiring harness between circuit breaker 81 Resis-
4 Max. 1 z
or defective contact in con- terminal – circuit breaker 82 terminal tance
Max. 1 z
Max. 1 z
Possible causes
value in normal
Max. 1 z
Max. 1 z
terminal – circuit breaker 82 terminal tance
circuit)
Max. 1 z
Max. 1 z
Max. 1 z
6 Defective engine controller J3P Starting switch Voltage
Between (3), (4) –
ON 20 – 30 V
(1), (2)
60 HM400-2
Circuit diagram related to engine controller power supply
HM400-2 61
Failure code [CA352] Abnormally low voltage in sensor power supply 11

Action code Failure code Abnormally low voltage in sensor power supply 1
Trouble
Contents of
• Voltage in sensor power supply 1 (5V) circuit of engine controller is abnormally low.
trouble
Action of
• Common rail pressure sensor limits output and continues operation (limits common rail pressure).
controller
Problem that
machine
Related
information

and standard
state
62 HM400-2
HM400-2 63
Failure code [CA386] Abnormally high voltage in sensor power supply 11

Action code Failure code Abnormally high voltage in sensor power supply 1
Trouble
Contents of
• Voltage in sensor power supply 1 (5V) circuit of engine controller is abnormally high.
trouble
Action of
• Common rail pressure sensor limits output and continues operation (limits common rail pressure).
controller
Problem that
machine
Related
information

first.
Defective sensor (Internal is disconnected, if
2
defect) mark E of failure Common rail
Connector PFUEL
code disappears, that pressure sensor
it.
3 Max. 1 z
or defective contact in con- – PFUEL (female) (1) tance
Possible causes nector)
and standard Wiring harness between ENG (female) (47) Resis-
Max. 1 z
value in normal – PFUEL (female) (3) tance
– PFUEL (female) (1) tance
circuit)
Min. 1 Mz
harness) Resis-
– PFUEL (female) (1) and between ENG Min. 1 Mz
tance
(female) (47) – PFUEL (female) (3)
ENG Voltage
Between (33) – (47) 4.75 – 5.25 V
64 HM400-2
Circuit diagram related to engine controller sensor power supply 1 (5 V)
HM400-2 65

© 2009 KOMATSU
All Rights Reserved
66 HM400-2
SEN01111-02
HM400-2

HM400-2 2001 and up
Failure code [CA431] Trouble in idle validation switch.................................................................................... 4
Failure code [CA432] Trouble in idle validation process ................................................................................. 7
Failure code [CA441] Abnormally low voltage in power supply ...................................................................... 7
Failure code [CA442] Abnormally high voltage in power supply ..................................................................... 8
Failure code [CA449] Abnormally high common rail pressure 2..................................................................... 8
Failure code [CA451] Abnormally high common rail pressure...................................................................... 10
Failure code [CA452] Abnormally low common rail pressure ....................................................................... 12
Failure code [CA553] Abnormally high common rail pressure 1................................................................... 12
Failure code [CA554] In-range error in common rail pressure sensor .......................................................... 13
Failure code [CA559] Supply pump low pressure 1...................................................................................... 15
Failure code [CA689] Trouble in engine Ne speed sensor ........................................................................... 18
Failure code [CA731] Phase error in engine Bkup speed sensor ................................................................. 20
Failure code [CA757] Loss of all data in engine controller............................................................................ 20
Failure code [CA778] Trouble in engine Bkup speed sensor........................................................................ 22
Failure code [CA1228] Trouble in EGR valve servo 1 .................................................................................. 24
Failure code [CA1625] Trouble in EGR valve servo 2 .................................................................................. 25
HM400-2 1
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit ................................................... 26
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit................................................ 28
Failure code [CA1628] Trouble in bypass valve servo 1 ............................................................................... 29
Failure code [CA1629] Trouble in bypass valve servo 2 ............................................................................... 30
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor ................................................... 32
Failure code [CA1632] Abnormally low signal in bypass valve lift sensor..................................................... 34
Failure code [CA1633] Trouble in KOMNET ................................................................................................. 36
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor................................................ 38
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor .............................................. 40
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply ......................................... 42
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply........................................... 44
Failure code [CA2249] Low pressure in supply pump 2................................................................................ 44
Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor .......................................... 46
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor............................................ 48
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit....................................................... 50
Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit ................................................... 52
Failure code [CA2555] Disconnection in intake air heater relay ................................................................... 52
Failure code [CA2556] Short circuit in intake air heater relay ....................................................................... 54
2 HM400-2
HM400-2 3
Failure code [CA431] Trouble in idle validation switch 1

Action code Failure code Trouble in idle validation switch
Trouble
Contents of
• Both of signals 1 and 2 of idle validation switch are open or there is trouble in ground circuit.
trouble
Action of
• Operates normally according to throttle sensor (E01 Testing and maintenance)
controller
Problem that
appears on • None in particular.
machine
Related
information
Applied serial number: – 2188
AS1 Signal name Voltage
Defective accelerator pedal Between (5) – (4) Signal 1
1 See Fig. 1
(Internal defect) Between (6) – (4) Signal 2
Max. 1 z
2
nector) Max. 1 z
Max. 1 z
and standard ing without turning starting switch ON.
state Ground fault in wiring har- Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
Wiring harness between J2P (female) (32) –
Voltage Max. 1 V
Hot short (Short circuit with AS1 (female) (4)
4
24V circuit) in wiring harness Wiring harness between J2P (female) (11) –
Voltage Max. 1 V
AS1 (female) (5)
Voltage Max. 1 V
AS1 (female) (6)
5 Defective engine controller J2P Signal name Voltage
Between (11) – (32) Signal 1
See Fig. 1
4 HM400-2
Applied serial number: 2189 and up

AS1 Signal name Voltage
Defective accelerator pedal See Fig. 1
1 Between (6) – (4) Signal 2
(Internal defect)
Between AS (1) – (2) 5V
Max. 1 z
Max. 1 z
2
nector) Max. 1 z
Wiring harness between ATC1 (female) (4) Resis-
Min.1 Mz
– AS2 (female) (2) tance
Min.1 Mz
– AS2 (female) (1) tance
and standard
state AS1 (female) (4) tance
Min. 1 Mz
Min. 1 Mz
Voltage Max. 1 V
Hot short (Short circuit with AS1 (female) (4)
4
24V circuit) in wiring harness Wiring harness between J2P (female) (11) –
Voltage Max. 1 V
AS1 (female) (5)
Voltage Max. 1 V
AS1 (female) (6)
5 Defective engine controller J2P Signal name Voltage
See Fig. 1
1) Turn starting switch OFF
2) Disconnect AS2 connector
Defective transmisson con- 3) Disconnect ATC3,ATC1 connector
6 4) Connect T-adapter to ATC3, ATC1 connector
troller
5) Turn starting switch ON and carry out troubleshooting
Between ATC3 (34) – ATC1 (4) Voltage 5V
HM400-2 5
Circuit diagram related to idle validation switch
Fig. 1
Pedal: Stroke of accelerator pedal

Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Sig2: Signal voltage of idle validation switch 1
Sig3: Signal voltage of idle validation switch 2
Lo: Switch circuit is closed
Hi: Switch circuit is open
Switch gap: Overlap between signals of switch 1 and switch 2
6 HM400-2
Failure code [CA432] Trouble in idle validation process 1

Action code Failure code Trouble in idle validation process
Trouble
Contents of • Throttle potentiometer signal of accelerator pedal is different from idle validation switch signals 1
trouble and 2.
• Turns caution lamp ON and sounds alarm buzzer.
Action of
• When throttle is fixed to low idle or pedal is released, engine speed is set to low idle. When pedal is
controller
pressed, engine speed is set to medium speed.
Problem that
• When accelerator pedal is pressed, engine speed does not rise from low idle or does not rise above
appears on
medium speed.
machine
Related
information

and standard
state
Failure code [CA441] Abnormally low voltage in power supply 1

Action code Failure code Abnormally low voltage in power supply
Trouble
Contents of
• Voltage in power supply circuit of engine controller is abnormally low.
trouble
Action of
controller
Problem that
machine

and standard
state
HM400-2 7
Failure code [CA442] Abnormally high voltage in power supply 1

Action code Failure code Abnormally high voltage in power supply
Trouble
Contents of
• Voltage in power supply circuit of engine controller is abnormally high.
trouble
Action of
controller
Problem that
machine

and standard
state
Failure code [CA449] Abnormally high common rail pressure 2 1

Action code Failure code Abnormally high common rail pressure 2
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Problem that
machine
Related • Common rail pressure can be checked with monitoring function.
information (Monitoring code: ENGINE - RAIL PRESS - 36400)

and standard
state
8 HM400-2
HM400-2 9
Failure code [CA451] Abnormally high common rail pressure 1

Action code Failure code Abnormally high common rail pressure
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure.
trouble
Action of
controller
Problem that
machine
Related • Condition of common rail pressure sensor signal can be checked with monitoring function.

1
PFUEL Voltage
Defective common rail pres- Between (1) – (3) Power supply 4.75 – 5.25 V
2
sure sensor (Internal defect) Between (2) – (3) Signal 0.25 – 4.6 V
Max. 1 z
ness (Disconnection in wiring – PFUEL (female) (1) tance
3
nector) Max. 1 z
Possible causes Wiring harness between ENG (female) (47) Resis-
value in normal
Min. 1 Mz
Min. 1 Mz
Resis-
tance
Short circuit in wiring har- (female) (25) – PFUEL (female) (2)
harness) Resis-
tance
Resis-
tance
10 HM400-2
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller ENG Voltage
state Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
HM400-2 11
Failure code [CA452] Abnormally low common rail pressure 1

Action code Failure code Abnormally low common rail pressure
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally low pressure.
trouble
Action of
controller
Problem that
machine

and standard
state
Failure code [CA553] Abnormally high common rail pressure 1 1

Action code Failure code Abnormally high common rail pressure 1
Trouble
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
controller
Problem that
machine

first.
Improper fuel may be used. Check used fuel directly (for high vis-
2 Use of improper fuel
cosity).
Defective electrical system of Electrical system of common rail pressure sensor may be defec-
Possible causes 3
common rail pressure sensor tive. Carry out troubleshooting for failure code [CA451].
and standard
value in normal Defective mechanical system
Mechanical system of common rail pressure sensor may be defec-
state 4 of common rail pressure sen-
tive. Check it directly.
sor
Check overflow valve for breakage of spring, wear of seat, and
5 Defective overflow valve
sticking of ball.
Clogged overflow valve pip-
6 Overflow valve piping may be clogged. Check it directly.
ing
7 Defective pressure limiter Pressure limiter may have mechanical trouble. Check it directly.
12 HM400-2
Failure code [CA554] In-range error in common rail pressure sensor 1

Action code Failure code In-range error in common rail pressure sensor
Trouble
Contents of
• Common rail pressure sensor circuit has in-range error in it.
trouble
Action of
controller
Problem that
machine

and standard
state
HM400-2 13
14 HM400-2
Failure code [CA559] Supply pump low pressure 1 1

Action code Failure code Supply pump low pressure 1
Trouble
Contents of
• Low pressure (level 1) is detected in supply pump.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine

first.
2 Use of improper fuel Improper fuel may be used. Check used fuel directly.
a For contents of troubleshooting, see Note 1. For measurement
of pressure in fuel low-pressure circuit, see Testing and adjust-
Defective low-pressure cir- ing, Measuring fuel pressure.
3
cuit device
Pressure in fuel low-pressure Min. 0.15 MPa
circuit (High idle) {Min. 1.5 kg/cm2}
4 Clogged filter or strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electrical defect. Carry out trouble-
Defective electrical system of
5 shooting for failure codes [CA271], [CA272], [CA273], and
supply pump PCV
[CA274].
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring har-
Possible causes 6
sure sensor ness for damage.
and standard
value in normal a For measurement of leakage from pressure limiter, see Testing
state and adjusting, Measuring fuel return rate and fuel leakage.
7 Defective pressure limiter Leakage from pressure limiter
(Operation equivalent to rating Max. 10 cc/min
(stall load))
a For measurement of limit of return (spill) from injector, see Test-
ing and adjusting, Measuring fuel return rate and fuel leakage.
Speed at operation equivalent to
Limit of return (spill) from injector
rating (stall load)
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached "Check sheet for rail
pressure low error".
HM400-2 15
Check sheet for rail pressure low error
Model HM400-2 Work No.

Machine serial No. # Date of check / /
Engine SAA6D140E-5 Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value Measured
Code Displayed item Checking condition ISO unit Good NG
(Reference value) value
Low idle r/min 700 – 750
01002 Engine speed High idle r/min 2,200 – 2,250
Torque converter stall r/min 2,000
Final accelerator Low idle % 0
31706
position High idle % 100
Final fuel injection
18600 rate command Torque converter stall mg/st — — —
(by weight)
4
Final common rail
36200 Torque converter stall MPa — — —
pressure command
Common rail pres-
36400 Torque converter stall MPa — — —
sure
Low idle CA — — —
Final injection tim-
36300 High idle CA — — —
ing command
Torque converter stall CA — — —
36500 Boost pressure Torque converter stall kPa — — —
Engine coolant tem-
04107 Low idle °C — — —
perature
14200 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Setting Reduced cylinder Checking condition ISO unit Good NG
No. 1 cylinder Low idle r/min — — —
5 No. 2 cylinder Low idle r/min — — —
Reduce No. 3 cylinder Low idle r/min — — —
each
cylinder No. 4 cylinder Low idle r/min — — —
16 HM400-2

C. Check of fuel circuit pressure Checking condition Unit Good NG
Fuel low-pressure circuit High idle or load equiva- MPa Min. 0.15
6
pressure lent to rating (at stall) {kg/cm2} {Min. 1.5}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E. Check of leakage and Standard value Measured

Checking condition Unit Good NG
return rate (Reference value) value
Leakage through pressure
11 Torque converter stall cc/min Max. 10
limiter
Torque converter stall
cc/min 960
1,600 rpm
cc/min 1,020
1,700 rpm
Torque converter stall Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm Leakage
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
HM400-2 17
Failure code [CA689] Trouble in engine Ne speed sensor 1

Action code Failure code Trouble in engine Ne speed sensor
Trouble
Contents of
• Engine Ne speed sensor circuit has trouble in it.
trouble
Action of
• Operates with signal of Bkup speed sensor.
controller
Problem that
• Engine stops if it has been running (when Bkup speed sensor also has trouble).
appears on
• Engine cannot be started if it has been stopped (when Ne speed sensor also has trouble).
machine
Related
information

Defective sensor power sup- If failure code [CA238] is indicated, carry out troubleshooting for it
1
ply system first.
Max. 1 z
ness (Disconnection in wiring – NE (female) (1) tance
2
nector) Max. 1 z
Max. 1 z
Min. 1 Mz
Min. 1 Mz
and standard – NE (female) (3) tance
Resis-
tance
Short circuit in wiring har- (female) (48) – NE (female) (2)
harness) Resis-
tance
Resis-
tance
Defective mount of sensor or Check Ne speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (flywheel) directly for
part defect.
If causes 1 – 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
sensor
carried out.)
out.)
18 HM400-2
Circuit diagram related to engine Ne speed sensor
HM400-2 19
Failure code [CA731] Phase error in engine Bkup speed sensor 1

Action code Failure code Phase error in engine Bkup speed sensor
Trouble
Contents of
• Engine Bkup sensor circuit detected abnormality in phase.
trouble
Action of
• Controls with signal of engine Ne speed sensor.
controller
Problem that
appears on
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
and standard 1
sensor system shooting for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
Failure code [CA757] Loss of all data in engine controller 1

Action code Failure code Loss of all data in engine controller
Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears on • Engine operates normally but may stop or may not be able to restart.
machine
Related
information

and standard
state
20 HM400-2
HM400-2 21
Failure code [CA778] Trouble in engine Bkup speed sensor 1

Action code Failure code Trouble in engine Bkup speed sensor
Trouble
Contents of
• Engine Bkup speed sensor circuit has trouble in it.
trouble
Action of
• Operates with signal of Ne speed sensor.
controller
Problem that
appears on
machine
Related
information

Defective sensor power sup- If failure code [CA187] or [CA227] is indicated, carry out trouble-
1
Max. 1 z
ness (Disconnection in wiring – G (female) (1) tance
2
nector) Max. 1 z
– G (female) (2) tance
Max. 1 z
Min. 1 Mz
Min. 1 Mz
and standard – G (female) (3) tance
Resis-
– G (female) (1) and between ENG (female) Min. 1 Mz
tance
Short circuit in wiring har- (47) – G (female) (2)
harness) Resis-
tance
(26) – G (female) (3)
Resis-
tance
(29) – G (female) (3)
Defective mount of sensor or Check Bkup speed sensor directly for defective mount (defective
5 defective rotation sensing clearance) or check rotation sensing part (in supply pump) directly
part for defect.
If causes 1 – 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup
6 be defective. (Since trouble is in system, troubleshooting cannot
speed sensor
be carried out.)
out.)
22 HM400-2
Circuit diagram related to engine Bkup speed sensor
HM400-2 23
Failure code [CA1228] Trouble in EGR valve servo 1 1

Action code Failure code Trouble in EGR valve servo 1
Trouble
Contents of
• EGR valve servo has trouble (level 1) in it.
trouble
Action of
• Performs open control.
controller
Problem that
appears on
machine
Related • Operating condition of EGR valve can be checked with monitoring function.
information (Monitoring code: ENGINE - EGR VALVE POS - 18100)

If another failure code is indicated, carry out troubleshooting for it
first.
a For check of engine oil pressure, see TESTING AND ADJUST-
ING, Measuring engine oil pressure.
Engine Engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for "S-
and standard 12 Oil pressure lowers" in S mode.
value in normal Defective oil pump for EGR Pump and relief valve for EGR valve circuit may be defective.
state 3
valve Check it directly.
Defective oil feed piping for Oil feed piping for EGR valve circuit may be defective. Check it
4
EGR valve directly.
Defective oil return piping for Oil return piping for EGR valve circuit may be defective. Check it
5
EGR valve directly.
Mechanical section of EGR valve may be defective. Check it
6 Defective EGR valve
directly.
out.)
24 HM400-2
Failure code [CA1625] Trouble in EGR valve servo 2 1

Action code Failure code Trouble in EGR valve servo 2
Trouble
Contents of
• EGR valve servo has trouble (level 2) in it.
trouble
Action of • Limits engine output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
machine
Related • Operating condition of EGR valve can be checked with monitoring function.

and standard
state
HM400-2 25
Failure code [CA1626] Short circuit in bypass valve solenoid drive

circuit 1
Action code Failure code Short circuit in bypass valve solenoid drive circuit
Trouble
Contents of
• There is short circuit in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

Defective bypass valve sole- ing without turning starting switch ON.
1
noid (Internal defect) BP (male) Resistance
Between (1) – (2) 10 – 21 z
2 Max. 1 z
or defective contact in con- – BP (female) (1) tance
Max. 1 z
– BP (female) (2) tance
and standard Ground fault in wiring har-
state – BP (female) (1) tance
circuit)
Min. 1 Mz
– BP (female) (2) tance
Hot short (Short circuit with Wiring harness between ENG (female) (31)
4 Voltage Max. 1 V
24V circuit) in wiring harness – BP (female) (1)
Voltage Max. 1 V
– BP (female) (2)
Between (31) – (11) 10 – 21 z
26 HM400-2
Circuit diagram related to bypass valve solenoid and lift sensor
HM400-2 27
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit1

Action code Failure code Disconnection in bypass valve solenoid drive circuit
Trouble
Contents of
• There is disconnection in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
28 HM400-2
Failure code [CA1628] Trouble in bypass valve servo 1 1

Action code Failure code Trouble in bypass valve servo 1
Trouble
Contents of
• Bypass valve servo has trouble (level 1) in it.
trouble
Action of
• Performs open control.
controller
Problem that
appears on
machine
Related • Operating condition of bypass valve can be checked with monitoring function.
information (Monitoring code: ENGINE - BPS VALVE POS - 18200)

If another failure code is indicated, carry out troubleshooting for it
first.
a For check of engine oil pressure, see TESTING AND ADJUST-
ING, Measuring engine oil pressure.
Engine Engine oil pressure
2 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
High idle 0.21 MPa {2.1 kg/cm2}
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for "S-
and standard 12 Oil pressure lowers" in S mode.
value in normal Defective oil pump for Oil pump and relief valve for bypass valve circuit may be defective.
3
state bypass valve Check it directly.
Defective oil feed piping for Oil feed piping for bypass valve circuit may be defective. Check it
4
bypass valve directly.
Defective oil return piping for Oil return piping for bypass valve circuit may be defective. Check it
5
bypass valve directly.
Mechanical section of bypass valve may be defective. Check it
6 Defective bypass valve
directly.
out.)
HM400-2 29
Failure code [CA1629] Trouble in bypass valve servo 2 1

Action code Failure code Trouble in bypass valve servo 2
Trouble
Contents of
• Bypass valve servo has trouble (level 2) in it.
trouble
Problem that
machine
Related • Operating condition of bypass valve can be checked with monitoring function.
information (Monitoring code: ENGINE-BPS VALVE POS-18200)

and standard
state
30 HM400-2
HM400-2 31
Failure code [CA1631] Abnormally high signal in bypass valve lift

sensor 1
Action code Failure code Abnormally high signal in bypass valve lift sensor
Trouble
Contents of
• Signal voltage in bypass valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
Related • Condition of bypass valve lift sensor signal can be checked with monitoring function.

1
SBP Voltage
Defective bypass valve lift
2 Between (1) – (2) Power supply 4.75 – 5.25V
Max. 1 z
ness (Disconnection in wiring – SBP (female) (1) tance
3
nector) Max. 1 z
– SBP (female) (2) tance

Max. 1 z
and standard – SBP (female) (3), (4) tance
Min. 1 Mz
Min. 1 Mz
– SBP (female) (3), (4) tance
Resis-
– SBP (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (38) – SBP (female) (2)
harness) Resis-
tance
(female) (29) – SBP (female) (3), (4)
Resis-
tance
(female) (29) – SBP (female) (3), (4)
32 HM400-2

value in normal 6 Defective engine controller
state ENG Voltage
Between (37) – (38) 4.75 – 5.25 V
Circuit diagram related to bypass valve lift sensor
HM400-2 33
Failure code [CA1632] Abnormally low signal in bypass valve lift

sensor 1
Action code Failure code Abnormally low signal in bypass valve lift sensor
Trouble
Contents of
• Signal voltage in bypass valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related • Condition of bypass valve lift sensor signal can be checked with monitoring function.

and standard
state
34 HM400-2
HM400-2 35
Failure code [CA1633] Trouble in KOMNET 1

Action code Failure code Trouble in KOMNET
Trouble
Contents of • Trouble occurred in KOMNET (CAN) communication circuit between engine controller, machine
trouble monitor, transmission controller, and retarder controller.
Action of
• Operates in default mode or maintains condition when abnormality occurs.
controller
Problem that
appears on
machine
Related
information

Defective CAN terminal ing without turning starting switch ON.
1
resistor (Internal defect) CAN1 (male), CAN2 (male) Resistance
Between (A) – (B) Approx. 120 ± 12 z
Disconnection in wiring har- Wiring harness between DPC4 (female) (3)
Resis-
ness (Disconnection in wiring – J2P (female) (47) or ATC2 (female) (22) – Max. 1 z
2 tance
or defective contact in con- BRC2 (female) (22)
nector) Wiring harness between DPC4 (female) (8)
Resis-
– J2P (female) (46) or ATC2 (female) (32) – Max. 1 z
tance
BRC2 (female) (32)
and standard Wiring harness between DPC4 (female) (3)
Ground fault in wiring har- Resis-
value in normal – J2P (female) (47) or ATC2 (female) (22) – Min. 1 Mz
3 ness (Short circuit with GND tance
state BRC2 (female) (22) or circuit branch end
circuit)
Wiring harness between DPC4 (female) (8)
Resis-
– J2P (female) (46) or ATC2 (female) (32) – Min. 1 Mz
tance
BRC2 (female) (32) or related circuit
Hot short (Short circuit with – J2P (female) (47) or ATC2 (female) (22) – Voltage Max. 1 V
4
24V circuit) in wiring harness BRC2 (female) (22) or related circuit
– J2P (female) (46) or ATC2 (female) (32) – Voltage Max. 1 V
BRC2 (female) (32) or related circuit
Defective engine controller,
If causes 1 – 4 are not detected, engine controller, machine moni-
machine monitor, transmis-
5 tor, transmission controller, or retarder controller may be defective.
sion controller, or retarder
controller
36 HM400-2
Circuit diagram related to CAN communication
HM400-2 37
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor1
Action code Failure code Abnormally low signal in EGR inlet pressure sensor
Trouble
Contents of
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally low.
trouble
Action of • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller • Limits engine output and continues operation.
Problem that
machine
Related
information

and standard
state
38 HM400-2
HM400-2 39
Failure code [CA1653] Abnormally high signal in EGR inlet pressure

sensor 1
Action code Failure code Abnormally high signal in EGR inlet pressure sensor
Trouble
Contents of
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally high.
trouble
Action of • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller • Limits engine output and continues operation.
Problem that
machine
Related • Condition of EGR valve inlet pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - EGR IN PRESS-A - 18001)

1
Defective EGR valve inlet PEVA Voltage
2 pressure sensor (Internal Between (1) – (2) Power supply 4.75 –5.25 V
defect)
Max. 1 z
ness (Disconnection in wiring – PEVA (female) (1) tance
3
nector) Max. 1 z
– PEVA (female) (2) tance

Max. 1 z
and standard – PEVA (female) (3) tance
Min. 1 Mz
Min. 1 Mz
Resis-
– PEVA (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – PEVA (female) (2)
harness) Resis-
tance
(female) (20) – PEVA (female) (3)
Resis-
tance
(female) (20) – PEVA (female) (3)
40 HM400-2

state ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve inlet pressure sensor
HM400-2 41
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply1
Action code Failure code Abnormally high voltage in throttle sensor power supply
Trouble
Contents of
• Voltage in throttle sensor power supply (5V) circuit is abnormally high.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective accelerator pedal is disconnected, if
1
(Internal defect) mark E of failure
Accelerator pedal Connector AS1
code disappears, that
it.
ness (Disconnection in wiring Wiring harness between J2P (female) (22) – Resis-
2 Max. 1 z
or defective contact in con- AS1 (female) (1) tance
nector) Wiring harness between J2P (female) (23) – Resis-
and standard
circuit)
Min. 1 Mz
4 ness (with another wiring Wiring harness between J2P (female) (22) –
harness) Resis-
AS1 (female) (1) and between J2P (female) Min. 1 Mz
tance
(23) – AS1 (female) (3)
J2P Voltage
Between (22) – (23) 4.75 – 5.25 V
42 HM400-2
Circuit diagram related to throttle sensor power supply of engine controller
HM400-2 43
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply1
Action code Failure code Abnormally low voltage in throttle sensor power supply
Trouble
Contents of
• Voltage in throttle sensor power supply (5V) circuit of engine controller is abnormally low.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
Failure code [CA2249] Low pressure in supply pump 2 1

Action code Failure code Low pressure in supply pump 2
Trouble
Contents of
• Very low pressure (level 2) is detected in supply pump.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
44 HM400-2
HM400-2 45
Failure code [CA2271] Abnormally high signal voltage in EGR valve lift
sensor 1
Action code Failure code Abnormally high signal voltage in EGR valve lift sensor
Trouble
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
Related • Condition of EGR valve lift sensor signal can be checked with monitoring function.

1
ply shooting for it first.
SEGR Voltage
Defective EGR valve lift sen-
sor (Internal defect)
Max. 1 z
ness (Disconnection in wiring – SEGR (female) (1) tance
3
nector) Max. 1 z
– SEGR (female) (2) tance

Max. 1 z
and standard – SEGR (female) (3), (4) tance
Min. 1 Mz
Min. 1 Mz
– SEGR (female) (3), (4) tance
Resis-
– SEGR (female) (1) and between ENG Min. 1 Mz
tance
Short circuit in wiring har- (female) (47) – SEGR (female) (2)
harness) Resis-
tance
(female) (19) – SEGR (female) (3), (4)
Resis-
tance
(female) (19) – SEGR (female) (3), (4)
46 HM400-2

state ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
HM400-2 47
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor 1
Action code Failure code Abnormally low signal voltage in EGR valve lift sensor
Trouble
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related • Condition of EGR valve lift sensor signal can be checked with monitoring function.

and standard
state
48 HM400-2
HM400-2 49
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit1
Action code Failure code Short circuit in EGR valve solenoid drive circuit
Trouble
Contents of
• There is short circuit in EGR valve solenoid drive circuit.
trouble
Problem that
machine
Related
information

Defective EGR valve sole- ing without turning starting switch ON.
1
noid (Internal defect) EGR (male) Resistance
Between (1) – (2) 10 – 21 z
2 Max. 1 z
or defective contact in con- – EGR (female) (1) tance
Max. 1 z
– EGR (female) (2) tance
and standard Ground fault in wiring har-
state – EGR (female) (1) tance
circuit)
Min. 1 Mz
– EGR (female) (2) tance
Hot short (Short circuit with Wiring harness between ENG (female) (22)
4 Voltage Max. 1 V
24V circuit) in wiring harness – EGR (female) (1)
Voltage Max. 1 V
– EGR (female) (2)
Between (22) – (11) 10 – 21 z
50 HM400-2
Circuit diagram related to EGR valve solenoid and lift sensor
HM400-2 51
Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit1

Action code Failure code Disconnection in EGR valve solenoid drive circuit
Trouble
Contents of
• There is disconnection in EGR valve solenoid drive circuit.
trouble
Problem that
machine
Related
information

and standard
state
Failure code [CA2555] Disconnection in intake air heater relay 1

Action code Failure code Disconnection in intake air heater relay
Trouble
Contents of
• There is disconnection in intake air heater relay circuit.
trouble
Action of
controller
Problem that
machine
Related • Engine coolant temperature can be checked with monitoring function.
information (Monitoring code: ENGINE - COOLANT - TEMP - 04104)

and standard
state
52 HM400-2
HM400-2 53
Failure code [CA2556] Short circuit in intake air heater relay 1

Action code Failure code Short circuit in intake air heater relay
Trouble
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
machine
• Engine controller has automatic preheating function, which is turned ON when engine coolant tem-
Related perature is below -5°C (for up to 30 seconds).
information • Engine coolant temperature can be checked with monitoring function.
(Monitoring code: ENGINE - COOLANT TEMP - 04104)

Defective intake air heater ing without turning starting switch ON.
1
relay (Internal trouble) R07 (male) Resistance
Between (1) – (2) 200 – 400 z
ness (Disconnection in wiring Wiring harness between J2P (female) (40) – Resis-
2 Max. 1 z
or defective contact in con- R07 (female) (1) tance
nector) Wiring harness between R07 (female) (42) Resis-
and standard – R07 (female) (2) tance
3 ness (Contact with GND cir- Min. 1 Mz
R07 (female) (1) tance
cuit)
Min. 1 Mz
4 Defective engine controller J2P Coolant temperature Voltage
Between (40) – chas- Above -5 °C Max. 1 V
sis ground Below -5 °C 20 – 30 V
54 HM400-2
Circuit diagram related to preheating/starting/charging of engine
HM400-2 55

© 2009 KOMATSU
All Rights Reserved
56 HM400-2
SEN01112-01
HM400-2

HM400-2 2001 and up
Failure code [DAF9KM] Wrong connection of connector ................................................................................ 3
Failure code [DAFRKR] Trouble in CAN communication (machine monitor).................................................. 4
Failure code [DAQ0KK] Lowering of source voltage....................................................................................... 6
Failure code [DAQ0KT] Trouble in non-volatile memory................................................................................. 8
Failure code [DAQ2KK] Trouble in solenoid power supply system............................................................... 10
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) .................................. 12
Failure code [DAQRKR] Trouble in CAN communication (Transmission controller)..................................... 14
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ..................................... 16
Failure code [DB10KT] Trouble in non-volatile memory ............................................................................... 16
Failure code [DB12KK] Trouble in solenoid power supply system ............................................................... 18
Failure code [DB13KK] Lowering of battery direct voltage ........................................................................... 20
Failure code [DB19KQ] Disagreement of model selection (Retarder controller)........................................... 22
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) ............................................. 22
Failure code [DB1RKR] Trouble in CAN communication (Retarder controller)............................................. 24
Failure code [DB2RKR] Trouble in CAN communication (Engine controller)................................................ 26
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal ..................................... 28
HM400-2 1
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve .................................................................... 30

Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve..................................................................... 31
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve ................................................................... 32
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve .................................................................. 33
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve .................................................................. 34
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve............................................................ 35
Failure code [DF10KA] Input of no lever signals........................................................................................... 36
Failure code [DF10KB] Input of multiple lever signals .................................................................................. 40
Failure code [DGF1KX] Transmission oil temperature out of range.............................................................. 44
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear)................................................ 46
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) ............................................. 48
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) ............................................ 50
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center).......................................... 52
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front)............................................... 54
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front)............................................. 56
Failure code [DGR6KX] Steering oil temperature out of range ..................................................................... 58
2 HM400-2
Failure code [DAF9KM] Wrong connection of connector 1

Action code Failure code Wrong connection of connector
Trouble
E03 DAF9KM (Machine monitor system)
Contents of
• Check signal of connector is different from internal setting of machine monitor.
trouble
Action of • Detects only at start.
machine monitor • Keeps trouble condition until starting switch is turned OFF.
Problem that
• Machine monitor mode selector switch cannot be selected.
appears on
• Headlamp high beam pilot lamp, turn signal pilot lamp, and output mode pilot lamp do not operate.
machine
Related
information

Wrong connection of connec- Connector DPC2A (female) may be connected to DPC3A (male)
1
tor by mistake. Check and connect it correctly, if connected wrongly.
Possible causes ness (Disconnection in wiring ing without turning starting switch ON.
and standard 2
or defective contact in con- Wiring harness between DPC2A (female) Resis-
value in normal nector) Max. 1 z
state
DPC2A Voltage
Between (5) – chassis ground 20 – 30 V
Circuit diagram related to connector check signal

a Display panel is the same as machine monitor.
HM400-2 3
Failure code [DAFRKR] Trouble in CAN communication (machine monitor) 1

Action code Failure code Trouble in CAN communication (machine monitor)
Trouble
E03 DAFRKR (Transmission controller system)
Contents of
• Transmission stops updating of data received from machine monitor.
trouble
Action of
• Keeps information collected when trouble occurred.
controller
Problem that
• If network has trouble, data which machine monitor obtains from each controller cannot be dis-
appears on
played normally.
machine
Related
information

1
resister (Internal defect) CAN1 (male), CAN2 (male) Resistance
Disconnection in wiring har- CAN1 (female) (A), CAN2 (female) (A), Resis-
Max. 1 z
ness (Disconnection in wiring DPC4 (female) (3), ATC2 (32), BRC2 (32) or tance
2
or defective contact in con- DL (female) (3)
nector) Wiring harness between J2P (female) (47) –
CAN1 (female) (B), CAN2 (female) (B), Resis-
Max. 1 z
DPC4 (female) (8), ATC2 (22), BRC2 (22) or tance
DL (female) (10)
Possible causes Wiring harness between J2P (female) (46) –
and standard CAN1 (female) (A), CAN2 (female) (A), Resis-
value in normal DPC4 (female) (3), ATC2 (32), BRC2 (32) or tance
state DL (female) (3)
circuit)
Min. 1 Mz
DL (female) (10)
CAN1 (female) (A), CAN2 (female) (A),
Voltage Max. 1 V
Hot short (Short circuit with DPC4 (female) (3), ATC2 (32), BRC2 (32) or
4
24V circuit) in wiring harness DL (female) (3)
CAN1 (female) (B), CAN2 (female) (B),
Voltage Max. 1 V
DPC4 (female) (8), ATC2 (22), BRC2 (22) or
DL (female) (10)
Defective machine monitor,
If causes 1 – 4 are not detected, machine monitor, engine control-
engine controller, transmis-
5 ler, transmission controller, or retarder controller may be defective.
sion controller or retarder
controller
4 HM400-2
HM400-2 5
Failure code [DAQ0KK] Lowering of source voltage 1

Action code Failure code Lowering of source voltage
Trouble
E03 DAQ0KK (Transmission controller system)
Contents of • While engine is running, voltages of both main power supply circuit and direct power supply circuit
trouble are below 18 V.
Action of
• Sets gear speed in neutral.
controller
Problem that
appears on • Machine is set in neutral suddenly during travel and cannot restart.
machine
• If failure code [AB00MA] (defective alternator function) is also displayed, carry out troubleshooting
Related
for it first.
information

Battery voltage Min. 24 V
1 Defective battery
Electrolyte specific gravity Min. 1.26
(See cause 5.)
Wiring harness between ATC3 (female) Resis-
Max. 1 z
(21), (31), (32), (33) – ground ER tance
Wiring harness between ATC3 (1), (11) – Resis-
Max. 1 z
Disconnection in wiring har- fuse BT2-No. 21 (22) tance
ness (Disconnection in wiring Wiring harness between fuse BT2-No. 21 Resis-
4 Max. 1 z
or defective contact in con- (21) – circuit breaker 84 terminal tance
Max. 1 z
Possible causes terminal – battery relay 66 terminal tance
and standard Wiring harness between battery relay 66 Resis-
value in normal Max. 1 z
terminal – battery (+) terminal tance
state
Max. 1 z
starting switch ACC tance
Wiring harness between ATC3 (female) Resis-
Max. 1 z
(21), (31), (32), (33) – ground ER tance
Max. 1 z
fuse BT2-No. 21 (22) tance
circuit)
Max. 1 z
Wiring harness between battery relay 66 Resis-
Max. 1 z
Max. 1 z
6 HM400-2

Possible causes and carry out troubleshooting.
and standard ATC3 Voltage
6 Between (1), (11) – (21), (31),
state troller 20 – 30 V
(32), (33)
Between (14), (24) – (21), (31),
20 – 30 V
(32), (33)
Circuit diagram related to transmission controller power supply
HM400-2 7
Failure code [DAQ0KT] Trouble in non-volatile memory 1

Action code Failure code Trouble in non-volatile memory
Trouble
E01 DAQ0KT (Transmission controller system)
Contents of • Non-volatile memory in transmission controller has trouble in it.
trouble • When starting switch was turned OFF, finishing process was not carried out normally.
Action of
• Controls model selection and option setting with default values.
controller
Problem that
• Control parameters of machine may change and gearshift shock of transmission and seating shock
appears on
of hoist may increase.
machine
• Perform initial setting and adjustment of transmission controller to be performed after replacement
Related
(See Testing and adjusting, Setting and adjusting each device).
information
• Method of reproducing failure code: Turn the starting switch ON.

and standard Troubleshooting cannot be carried out since the trouble is in the
1 controller. (If there is not any visible trouble in the machine, the
state troller
controller may be used as it is.)
8 HM400-2
HM400-2 9
Failure code [DAQ2KK] Trouble in solenoid power supply system 1

Action code Failure code Trouble in solenoid power supply system
Trouble
E03 DAQ2KK (Transmission controller system)
Contents of
• While controller power supply circuit is normal, voltage in solenoid power supply circuit is below 18 V.
trouble
Action of • Turns transmission cut-off relay OFF.
controller • Sets gear speed in neutral.
Problem that
• Machine is set in neutral suddenly during travel and cannot restart.
appears on
• Dump body cannot be operated.
machine
Related
information

(See cause 4.)
Wiring harness between ATC3 (2), (12), (22) Resis-
Max. 1 z
Disconnection in wiring har- – fuse BT3-No. 32 (14) tance
3 Max. 1 z
Max. 1 z
Battery relay 66 terminal – battery (+) ter- Resis-
minal tance
and standard
Wiring harness between ATC3 (2), (12), (22) Resis-
Max. 1 z
– fuse BT3-No. 32 (14) tance
circuit)
Max. 1 z
Max. 1 z
minal tance
5 ATC3 Voltage
troller
Between (2), (12), (22) – (21),
20 – 30 V
(31), (32), (33)
10 HM400-2
Circuit diagram related to solenoid power supply system
HM400-2 11
Failure code [DAQ9KQ] Disagreement of model selection (Transmission

controller) 1
Action code Failure code Disagreement of model selection (Transmission controller)
Trouble
E03 DAQ9KQ (Machine monitor system)
Contents of
• Transmission controller detected disagreement of model selection.
trouble
Action of
machine monitor
Problem that
appears on • If machine travels at it is, transmission may be damaged.
machine
Related
information

Wrong model may be set by machine monitor. After replacing
Wrong setting of model by
1 machine monitor or transmission controller, set it correctly accord-
Possible causes machine monitor
ing to Testing and adjusting.
and standard
value in normal Installation of wrong trans- Wrong transmission controller may be installed. Check its part No.
2
state mission controller and replace it with correct one, if necessary.
If causes 1 – 2 are not detected, machine monitor may be defec-
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
12 HM400-2
HM400-2 13
Failure code [DAQRKR] Trouble in CAN communication (Transmission

controller) 1
Action code Failure code Trouble in CAN communication (Transmission controller)
Trouble
E03 DAQRKR (Machine monitor system)
Contents of
• Machine monitor cannot receive information from transmission controller.
trouble
Action of
• Keeps information collected when trouble occurred.
machine monitor
Problem that
• Information obtained from transmission controller and special functions cannot be operated or dis-
appears on
played.
machine
Related
information

1
Max. 1 z
2
Max. 1 z
DL (female) (10)
circuit)
Min. 1 Mz
DL (female) (10)
Voltage Max. 1 V
4
Voltage Max. 1 V
DL (female) (10)
controller
14 HM400-2
HM400-2 15
Failure code [DAQRMA] Disagreement of option setting (Transmission

controller) 1
Action code Failure code Disagreement of option setting (Transmission controller)
Trouble
E03 DAQRMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in controller.
• Keeps gear speed in neutral.
Action of
• Controls with option setting saved in controller.
machine monitor
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Problem that
appears on • Machine is set in neutral and cannot restart.
machine
Related • Option setting signal is obtained from transmission controller through network.
information • Method of reproducing failure code: Turn starting switch ON.

Possible causes
Wrong option setting in Option may be set wrongly in machine monitor. Set it correctly
and standard 1
machine monitor according to Testing and adjusting.
value in normal
state If cause 1 is not detected, machine monitor may be defective.
Failure code [DB10KT] Trouble in non-volatile memory 1

Action code Failure code Trouble in non-volatile memory
Trouble
E01 DB10KT (Retarder controller system)
Contents of
• Non-volatile memory in transmission controller has trouble in it.
trouble
Action of • Controls model selection and option setting with default values.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Control parameters of machine may change and power may increase or decrease.
machine
• Perform initial setting and adjustment of retarder controller to be performed after replacement (See
Related
Testing and adjusting, Setting and adjusting each device).
information
• Method of reproducing failure code: Turn the starting switch ON.

and standard
value in normal Troubleshooting cannot be carried out since the trouble is in the
state controller.
16 HM400-2
HM400-2 17
Failure code [DB12KK] Trouble in solenoid power supply system 1

Action code Failure code Trouble in solenoid power supply system
Trouble
E01 DB12KK (Retarder controller system)
Contents of • While retarder controller power supply circuit is normal, voltage in solenoid power supply circuit is
trouble below 18 V.
Action of • Turns all output circuits OFF.
controller • Turns 24V power supply for sensors OFF.
Problem that
• No systems of retarder controller operate (Retarder and brake cooling valve).
appears on
• Failure codes [DHU2KX] and [DHU3KX] are also displayed.
machine
• If failure code [DAQ0KK] or [DAQ2KK] (transmission controller power supply) is also displayed,
Related
carry out troubleshooting for it first.
information

(See cause 4.)
Wiring harness between BRC3 (2), (12), Resis-
Max. 1 z
Disconnection in wiring har- (22) – fuse BT3-No. 32 (12) tance
3 Max. 1 z
Max. 1 z
minal tance
and standard
Wiring harness between BRC3 (2), (12), Resis-
Max. 1 z
(22) – fuse BT3-No. 32 (12) tance
circuit)
Max. 1 z
Max. 1 z
minal tance
5 Defective retarder controller BRC3 Voltage
Between (2), (12), (22) – (21),
20 – 30 V
(31), (32), (33)
18 HM400-2
Circuit diagram related to retarder controller solenoid power supply system
HM400-2 19
Failure code [DB13KK] Lowering of battery direct voltage 1

Action code Failure code Lowering of battery direct voltage
Trouble
E03 DB13KK (Transmission controller system)
Contents of
• Voltage in power supply circuit of retarder controller is below 18 V.
trouble
Action of
• Turns all outputs OFF.
controller
Problem that
appears on • Retarder does not operate.
machine
• If failure code [DAQ0KK] or [DAQ2KK] (transmission controller power supply) is also displayed,
Related
carry out troubleshooting for it first.
information

Battery voltage Min. 24 V
1 Defective battery
Electrolyte specific gravity Min. 1.26
(See cause 5.)
Wiring harness between BRC3 (female) Resis-
Max. 1 z
(21), (31), (32), (33) – ground ER tance
Wiring harness between BRC3 (1), (11) – Resis-
Max. 1 z
Disconnection in wiring har- fuse BT2-No. 19 (18) tance
4 Max. 1 z
and standard
value in normal Wiring harness between battery relay 66 Resis-
Max. 1 z
state terminal – battery (+) terminal tance
Max. 1 z
Wiring harness between BRC3 (1), (11) – Resis-
Max. 1 z
Ground fault in wiring har- Max. 1 z
circuit) Wiring harness between circuit breaker 82 Resis-
Max. 1 z
Wiring harness between battery relay 66 Resis-
Max. 1 z
6 Defective retarder controller BRC3 Voltage
Between (1), (11) – (21), (31),
20 – 30 V
(32), (33)
20 HM400-2
Circuit diagram related to retarder controller power supply
HM400-2 21
Failure code [DB19KQ] Disagreement of model selection (Retarder

controller) 1
Action code Failure code Disagreement of model selection (Retarder controller)
Trouble
E03 DB19KQ (Machine monitor system)
Contents of • Information of model selection input from machine monitor when starting switch is turned ON is dif-
trouble ferent from model selection saved in retarder controller.
Action of
• Turns all outputs OFF.
machine monitor
Problem that
appears on • When starting operation is performed, machine does not start.
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.

Possible causes Model may be set wrongly in machine monitor. When machine
Wrong model selection in
and standard 1 monitor or retarder controller is replaced, set it correctly according
machine monitor
value in normal to Testing and adjusting.
state Defective transmission con- Wrong transmission controller may be installed. Check its part No.
2
troller and install correct transmission controller.
Failure code [DB1QMA] Disagreement of option setting (Retarder

controller) 1
Action code Failure code Disagreement of option setting (Retarder controller)
Trouble
E03 DB1QMA (Machine monitor system)
Contents of • Information of option setting sent from machine monitor when starting switch is turned ON is differ-
trouble ent from option setting saved in retarder controller.
• Turns machine monitor and option system caution lamp ON and sounds alarm buzzer.
Action of
• Controls with option setting saved in controller.
machine monitor
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on
machine
Related • Perform initial setting and adjustment of retarder controller to be performed after replacement.

Possible causes Option may be set wrongly in machine monitor. When machine
Wrong option setting in
and standard 1 monitor or retarder controller is replaced, set it correctly according
machine monitor
value in normal to Testing and adjusting.
state If cause 1 is not detected, machine monitor may be defective.
22 HM400-2
HM400-2 23
Failure code [DB1RKR] Trouble in CAN communication (Retarder

controller) 1
Action code Failure code Trouble in CAN communication (Retarder controller)
Trouble
E03 DB1RKR (Transmission controller system)
Contents of
• Updating of date received from retarder controller is stopped.
trouble
Action of • Fixes AISS to Lo or Hi (Controls with data received last).
controller • Keeps information collected when trouble occurred.
Problem that
• Information obtained from retarder controller is not displayed.
appears on
• Special functions do not operate.
machine
Related
information

1
Max. 1 z
2
Max. 1 z
DL (female) (10)
circuit)
Min. 1 Mz
DL (female) (10)
Voltage Max. 1 V
4
Voltage Max. 1 V
DL (female) (10)
controller
24 HM400-2
HM400-2 25
Failure code [DB2RKR] Trouble in CAN communication (Engine controller) 1

Action code Failure code Trouble in CAN communication (Engine controller)
Trouble
E03 DB2RKR (Transmission controller system)
Contents of
• Updating of date received from engine controller is stopped.
trouble
Action of • Keeps gear speed.
controller • Keeps gearshift lever in N position.
Problem that
• Information obtained from engine controller is not displayed.
appears on
• Special functions do not operate.
machine
Related
information

1
Max. 1 z
2
Max. 1 z
DL (female) (10)
Possible causes CAN1 (female) (A), CAN2 (female) (A), Resis-
and standard DPC4 (female) (3), ATC2 (32), BRC2 (32) or tance
value in normal DL (female) (3)
circuit)
state Wiring harness between J2P (female) (47) –
Min. 1 Mz
DL (female) (10)
Voltage Max. 1 V
4
Voltage Max. 1 V
DL (female) (10)
Defective engine controller Engine controller power supply may be defective. Carry out trou-
5
power supply bleshooting for "Failure code CA111".
controller
26 HM400-2
HM400-2 27
Failure code [DD1ML4] Disagreement of accelerator-linked retarder

switch signal 1
Action code Failure code Disagreement of accelerator-linked retarder switch signal
Trouble
E01 DD1ML4 (Transmission controller system)
• Switch 1 signal and switch 2 signal of accelerator-linked retarder switch are turned ON simulta-
Contents of neously.
trouble • Switch 1 signal and switch 2 signal of accelerator-linked retarder switch are turned OFF simulta-
neously.
Action of
• Stops operation of accelerator-linked retarder.
machine monitor
Problem that
appears on • Accelerator-linked retarder does not operate.
machine
• Signal of accelerator-linked retarder switch is input to machine monitor and then its information is
transmitted to transmission controller through communication system.
Related • Operation of accelerator-linked retarder switch can be checked with monitoring function.
information (Monitoring code: MONITOR PANEL - D-IN---0------7 - 40900)
(Monitoring code: MONITOR PANEL - D-IN-24-----31 - 40903)

(See cause 5.)
Accelerator-linked
ACC (female) Resistance
retarder switch
Defective accelerator-linked Upper Min. 1 Mz
3 retarder switch (Internal Between (1) – (2)
Lower Max. 1 z
defect)
Upper Max. 1 z
Between (1) – (3)
Lower Min. 1 Mz
Disconnection in wiring har- Wiring harness between DPC2A (female) Resis-
Max. 1 z
ness (Disconnection in wiring (10) – ACC (female) (3) tance
Possible causes 4
and standard nector) Max. 1 z
(11) – ACC (female) (2) tance
value in normal
state Wiring harness between AAC (male) (1) – Resis-
Max. 1 z
Wiring harness between DPC2A (female) Resis-
circuit) Wiring harness between DPC3A (female) Resis-
Min. 1 Mz
Wiring harness between AAC (male) (1) – Resis-
Min. 1 Mz
Hot short (Short circuit with Wiring harness between DPC2A (female)
6 Voltage Max. 1 V
24V circuit) in wiring harness (10) – ACC (female) (3)
Wiring harness between DPC3A (female)
Voltage Max. 1 V
(11) – ACC (female) (2)
28 HM400-2

Accelerator-linked
DPC2A, DPC3A Voltage
retarder switch
Possible causes
7 Defective machine monitor Upper 20 – 30 V
and standard Between DPC2A (10)
value in normal – chassis ground Lower Max. 1 V
state
Between DPC3A (11) Upper Max. 1 V
– chassis ground Lower 20 – 30 V
troller
carried out.)
Circuit diagram related to accelerator-linked retarder switch

HM400-2 29
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve 1

Action code Failure code Trouble in Hi clutch flow sensor valve
Trouble
E03 DDTHKA (Transmission controller system)
Contents of • When output to Hi clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill
trouble switch is not turned ON.
Action of • Keeps current gear speed.
controller • If gearshift lever is set in "N", gear speed is kept in neutral.
• Gear cannot be shifted.
Problem that
• If gearshift lever is set in "N", machine cannot restart until it stops.
appears on
• Machine can travel in gear speeds which use Hi clutch.
machine
• Input of Hi clutch ECMV fill signal can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Start engine + travel at F2.

Defective Hi clutch ECMV fill CN11 (male) Gear speed Resistance
1
Between (1) – N Min. 1 Mz
chassis ground F2 Max. 1 z
Possible causes
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal 2
state or defective contact in con- Wiring harness between ATC3 (female) (30) Resis-
nector) Max. 1 z
Defective transmission con- ATC3 Gear speed Voltage
3
troller
Between (30) – N 20 – 30 V
chassis ground F2 Max. 1 V
Circuit diagram related to Hi clutch ECMV fill switch
30 HM400-2
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve 1

Action code Failure code Trouble in Lo clutch flow sensor valve
Trouble
E03 DDTJKA (Transmission controller system)
Contents of • When output to Lo clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill
Problem that
appears on
• Machine can travel in gear speeds which use Lo clutch.
machine
• Input of Lo clutch ECMV fill signal can be checked with monitoring function.
Related
information

Defective Lo clutch ECMV fill CN7 (male) Gear speed Resistance
1
Possible causes
value in normal 2
nector) Max. 1 z
Defective transmission con- ATC3 (female) Gear speed Voltage
3
troller
Between (20) – N 20 – 30 V
Circuit diagram related to Lo clutch ECMV fill switch
HM400-2 31
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve 1

Action code Failure code Trouble in 1st clutch flow sensor valve
Trouble
E03 DDTKKA (Transmission controller system)
Contents of • When output to 1st clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill
Problem that • Gear cannot be shifted.
appears on • If gearshift lever is set in "N", machine cannot restart until it stops.
machine • Machine can travel in gear speeds which use 1st clutch.
• Input of 1st clutch ECMV fill signal can be checked with monitoring function.
Related
information

Defective 1st clutch ECMV CN13 (male) Gear speed Resistance
1
Possible causes
value in normal 2
nector) Max. 1 z
3
troller
Between (40) – N 20 – 30 V
Circuit diagram related to 1st clutch ECMV fill switch
32 HM400-2
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve 1

Action code Failure code Trouble in 2nd clutch flow sensor valve
Trouble
E03 DDTLKA (Transmission controller system)
Contents of • When output to 2nd clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill
machine • Machine can travel in gear speeds which use 2nd clutch.
• Input of 2nd clutch ECMV fill signal can be checked with monitoring function.
Related
information

Defective 2nd clutch ECMV CN15 (male) Gear speed Resistance
1
Possible causes
value in normal 2
nector) Max. 1 z
3
troller
Between (9) – N 20 – 30 V
Circuit diagram related to 2nd clutch ECMV fill switch
HM400-2 33
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve 1

Action code Failure code Trouble in 3rd clutch flow sensor valve
Trouble
E03 DDTMKA (Transmission controller system)
Contents of • When output to 3rd clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from fill
machine • Machine can travel in gear speeds which use 3rd clutch.
• Input of 3rd clutch ECMV fill signal can be checked with monitoring function.
Related
information

Defective 3rd clutch ECMV CN17 (male) Gear speed Resistance
1
Possible causes
value in normal 2
nector) Max. 1 z
3
troller
Between (19) – N 20 – 30 V
Circuit diagram related to 3rd clutch ECMV fill switch
34 HM400-2
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve 1

Action code Failure code Trouble in reverse clutch flow sensor valve
Trouble
E03 DDTNKA (Transmission controller system)
Contents of • When output to reverse clutch ECMV solenoid valve is turned ON, clutch is engaged but signal from
trouble fill switch is not turned ON.
Problem that
appears on
• Machine can travel in gear speeds which use reverse clutch.
machine
• Machine cannot travel forward.
• Input of reverse clutch ECMV fill signal can be checked with monitoring function.
Related
• When machine is checked for cause 1, its travel speed at R1 gear speed reaches about 7 km/h.
information
• Method of reproducing failure code: Start engine + travel at R1.

Defective reverse clutch
1 ECMV fill switch (Internal CN9 (male) Gear speed Resistance
defect) Between (1) – N Min. 1 Mz
chassis ground R1 Max. 1 z
Possible causes
value in normal 2
nector) Max. 1 z
3
troller
Between (29) – N 20 – 30 V
chassis ground R1 Max. 1 V
Circuit diagram related to reverse clutch ECMV fill switch
HM400-2 35
Failure code [DF10KA] Input of no lever signals 1

Action code Failure code Input of no lever signals
Trouble
E03 DF10KA (Transmission controller system)
Contents of
• No lever signals are input.
trouble
Action of
• Controls with lever information before trouble.
controller
• Gear is shifted up above gear speed set with gearshift lever.
Problem that
• Gear is kept in neutral and machine cannot start.
appears on
• Travel direction cannot be changed.
machine
• All of gearshift lever position lamps are turned OFF.
• N position of gearshift lever can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - D-IN--0------7 - 40905)
information

Gearshift lever may have been pressed by some force other than
Wrong operation of gearshift gearing shifting effort. Check its condition.
1
lever Gearshift lever may be stopped at intermediate point between nor-
mal positions. Checks its condition.
SF1 Shift range Voltage
Between (3) – R2 20 – 30 V
chassis ground Other than above Max. 1 V
Between (4) – R1 20 – 30 V
Between (5) – N 20 – 30 V
Possible causes Between (6) – D 20 – 30 V
and standard chassis ground Other than above Max. 1 V
value in normal
Between (7) – 5 20 – 30 V
state
Defective gearshift lever chassis ground Other than above Max. 1 V
2
(Internal defect) Between (8) – 4 20 – 30 V
Between (9) – 3 20 – 30 V
Between (10) – 2 20 – 30 V
Between (11) – 1 20 – 30 V
SF1 HOLD switch Voltage
Between (12) – ON 20 – 30 V
chassis ground OFF Max. 1 V
36 HM400-2

Wiring harness between BT3 (14) – SF1 Resis-
Max. 1 z
(female) (1) tance
Max. 1 z
– SF1 (female) (3) tance
Max. 1 z
Max. 1 z
Disconnection in wiring har- Wiring harness between ATC2 (female) (15) Resis-
Max. 1 z
ness (Disconnection in wiring – SF1 (female) (6) tance
3
nector) Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
and standard
Max. 1 z
state – SF1 (female) (12) tance
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
circuit)
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
HM400-2 37

ATC1, ATC2 Shift range Voltage
Between ATC2 (35) – R2 20 – 30 V
Between ATC2 (25) – R1 20 – 30 V
Between ATC1 (6) – N 20 – 30 V
Between ATC2 (15) – D 20 – 30 V
Possible causes
and standard
value in normal Defective transmission con- 5 20 – 30 V
5 Between ATC2 (5) –
state troller
Between ATC2 (36) – 4 20 – 30 V
Between ATC2 (26) – 3 20 – 30 V
Between ATC2 (16) – 2 20 – 30 V
Between ATC2 (6) – 1 20 – 30 V
Between ATC2 (12) – HOLD 20 – 30 V
38 HM400-2
Circuit diagram related to gearshift lever signal
HM400-2 39
Failure code [DF10KB] Input of multiple lever signals 1

Action code Failure code Input of multiple lever signals
Trouble
E03 DF10KB (Transmission controller system)
Contents of
• Multiple lever signals are input simultaneously.
trouble
• Controls with signal of higher priority.
Action of (1): N > D > 5 > 4 > 3 > 2 > 1
controller (2): N > R2 > R1
• If signals of (1) and (2) above are input simultaneously, gear is set in neutral.
Problem that • Gear may be shifted up above gear speed set with gearshift lever.
appears on • Gear is kept in neutral and machine cannot start.
machine • All of gearshift lever position lamps are turned OFF.
• N position of gearshift lever can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - D-IN--0------7 - 40905)
information
• Method of reproducing failure code: Turn starting switch ON + operate gearshift lever.

SF1 Shift range Voltage
Between (3) – R2 20 – 30 V
Between (4) – R1 20 – 30 V
Between (5) – N 20 – 30 V
Between (6) – D 20 – 30 V
Possible causes Between (7) – 5 20 – 30 V
and standard chassis ground
Defective gearshift lever Other than above Max. 1 V
value in normal 1
state (Internal defect) Between (8) – 4 20 – 30 V
Between (9) – 3 20 – 30 V
Between (10) – 2 20 – 30 V
Between (11) – 1 20 – 30 V
SF1 HOLD switch Voltage
Between (12) – ON 20 – 30 V
chassis ground OFF Max. 1 V
40 HM400-2

Wiring harness between ATC2 (female) (35)
Voltage Max. 1 V
– SF1 (female) (3)
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
Hot short (Short circuit with Wiring harness between ATC2 (female) (5)
2 Voltage Max. 1 V
24V circuit) in wiring harness – SF1 (female) (7)
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
Voltage Max. 1 V
and standard and carry out troubleshooting.
value in normal
state ATC1, ATC2 Shift range Voltage
Between ATC2 (35) – R2 20 – 30 V
Between ATC2 (25) – R1 20 – 30 V
Between ATC1 (6) – N 20 – 30 V
Between ATC2 (15) – D 20 – 30 V
Defective transmission con- 5 20 – 30 V
troller
Between ATC2 (36) – 4 20 – 30 V
Between ATC2 (26) – 3 20 – 30 V
Between ATC2 (16) – 2 20 – 30 V
Between ATC2 (6) – 1 20 – 30 V
Between ATC2 (12) – HOLD 20 – 30 V
HM400-2 41
Circuit diagram related to gearshift lever signal
42 HM400-2
HM400-2 43
Failure code [DGF1KX] Transmission oil temperature out of range 1

Action code Failure code Transmission oil temperature out of range
Trouble
E03 DGF1KX (Transmission controller system)
• Voltage in transmission oil temperature sensor signal circuit is below 0.97 V (above150°C).
Contents of
• While torque converter oil temperature sensor voltage is below 3.75 V (above 55°C), voltage in
trouble
transmission oil temperature sensor signal circuit is above 4.56 V (below 15°C).
Action of
• Controls clutch oil pressure with oil temperature before trouble.
controller
Problem that
appears on • Gear shifting shock is increased.
machine
• Signal input from oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - TRANSMISSION OIL TEMP - 32500)
information (Monitoring code: TRANSMISSION - TRANSMISSION OIL TEMP - 32501)
• Method of reproducing failure code: Turn starting switch ON or start engine.

Defective transmission oil
1 temperature sensor (Internal CN24 (male) Brake oil temperature Resistance
defect) 25°C 37 – 50 kz
Between (1) – (2)
100°C 3.5 – 4.0 kz
2 Max. 1 z
and standard
state 3 ness (Short circuit with GND
circuit) Wiring harness between ATC1 (female) (3) Resis-
Min. 1 Mz
Hot short (Short circuit with and carry out troubleshooting.
4
24V circuit) in wiring harness Wiring harness between ATC1 (female) (3)
Voltage Max. 1 V
– CN24 (female) (1)
Defective transmission con- ATC1 (female) Brake oil temperature Resistance
5
troller
25°C 37 – 50 kz
Between (3) – (21)
100°C 3.5 – 4.0 kz
44 HM400-2
Circuit diagram related to transmission oil temperature sensor
HM400-2 45
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor

(rear) 1
Action code Failure code Ground fault in brake oil temperature sensor (rear)
Trouble
E01 DGR2KZ (Machine monitor system)
Contents of
• Voltage in signal circuit of brake oil temperature sensor (rear) is below 0.96 V.
trouble
Action of
machine monitor
Problem that
appears on • Oil temperature gauge does not move in failure mode of sensor.
machine
• Signal input from brake oil temperature sensor (rear) can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30202)
information (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30205)

M05 (male) Brake oil temperature Resistance
Defective brake oil tempera- 25°C Approx. 42.7 kz
1 ture sensor (rear) (Internal
30°C Approx. 35.1 kz
defect)
Between (1) – (2) 80°C Approx. 6.6 kz
ness (Disconnection in wiring Wiring harness between DCP3B (female) Resis-
2 Max. 1 z
Possible causes or defective contact in con- (8) – M05 (female) (1) tance
and standard nector) Wiring harness between DCP3B (female) Resis-
state
circuit) Wiring harness between DCP3B (female) Resis-
Min. 1 Mz
4 ness (with another wiring Wiring harness between DCP3B (female)
harness) Resis-
(8) – M05 (female) (1) and between DCP3B Min. 1 Mz
tance
(female) (6) – M05 (female) (2)
5 Defective machine monitor a Read monitoring code: 30202 (MONITOR PANEL - BRAKE OIL
T R) with rear-time function.
Displayed temperature True oil temperature
46 HM400-2
Circuit diagram related to brake oil temperature sensor (rear)

HM400-2 47
Failure code [DGR2L8] Disconnection in brake oil temperature sensor

(rear) 1
Action code Failure code Disconnection in brake oil temperature sensor (rear)
Trouble
E01 DGR2L8 (Machine monitor system)
Contents of • While brake oil temperature sensor (front) signal and brake oil temperature sensor (center) signal
trouble are above 60°C, brake oil temperature sensor (rear) signal is below 10°C.
Action of
machine monitor
Problem that
• Retarder oil temperature gauge is not displayed normally.
appears on
• If machine is used as it is, braking effect may lower.
machine
• Signal input from brake oil temperature sensor (rear) can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30202)
information (Monitoring code: MONITOR PANEL - BRAKE OIL T R - 30205)

1 ture sensor (rear) (Internal
defect)
value in normal ness (Disconnection in wiring Wiring harness between DCP3B (female) Resis-
2 Max. 1 z
nector) Wiring harness between DCP3B (female) Resis-
Max. 1 z
Hot short (Short circuit with ing without turning starting switch ON.
3
24V circuit) in wiring harness Wiring harness between DCP3B (female)
Voltage Max. 1 V
(8) – M05 (female) (1)
T R) with rear-time function.
48 HM400-2
Circuit diagram related to brake oil temperature sensor (rear)

HM400-2 49

(center) 1
Action code Failure code Ground fault in brake oil temperature sensor (center)
Trouble
Contents of
• Voltage in signal circuit of brake oil temperature sensor (center) is below 0.96 V.
trouble
Action of
machine monitor
Problem that
machine
• Signal input from brake oil temperature sensor (center) can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30203)
information (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30206)

1 ture sensor (center) (Internal
defect)
state Min. 1 Mz
harness) Resis-
tance
T M) with rear-time function.
50 HM400-2
Circuit diagram related to brake oil temperature sensor (center)

HM400-2 51

(center) 1
Action code Failure code Disconnection in brake oil temperature sensor (center)
Trouble
Contents of • While brake oil temperature sensor (front) signal and brake oil temperature sensor (rear) signal are
trouble above 60°C, brake oil temperature sensor (center) signal is below 10°C.
Action of
machine monitor
Problem that
appears on
machine
• Signal input from brake oil temperature sensor (center) can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30203)
information (Monitoring code: MONITOR PANEL - BRAKE OIL T M - 30206)

1 ture sensor (center) (Internal
defect)
2 Max. 1 z
Max. 1 z
Hot short (Short circuit with ing without turning starting switch ON.
3
24V circuit) in wiring harness Wiring harness between DCP3B (female)
Voltage Max. 1 V
(2) – M04 (female) (1)
T M) with rear-time function.
52 HM400-2
Circuit diagram related to brake oil temperature sensor (center)

HM400-2 53

(front) 1
Action code Failure code Ground fault in brake oil temperature sensor (front)
Trouble
Contents of
• Voltage in signal circuit of brake oil temperature sensor (front) is below 0.96 V.
trouble
Action of
machine monitor
Problem that
machine
• Signal input from brake oil temperature sensor (front) can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30201)
information (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30204)

1 ture sensor (front) (Internal
defect)
state Min. 1 Mz
harness) Resis-
tance
T F) with rear-time function.
54 HM400-2
Circuit diagram related to brake oil temperature sensor (front)
HM400-2 55

(front) 1
Action code Failure code Disconnection in brake oil temperature sensor (front)
Trouble
Contents of • While brake oil temperature sensor (center) signal and brake oil temperature sensor (rear) signal
trouble are above 60°C, brake oil temperature sensor (front) signal is below 10°C.
Action of
machine monitor
Problem that
appears on
machine
• Signal input from brake oil temperature sensor (front) can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30201)
information (Monitoring code: MONITOR PANEL - BRAKE OIL T F - 30204)

1 ture sensor (front) (Internal
defect)
2 Max. 1 z
Max. 1 z
circuit) Wiring harness between DCP3B (female)
Voltage Max. 1 V
(7) – M07 (female) (1)
T F) with rear-time function.
56 HM400-2
Circuit diagram related to brake oil temperature sensor (front)

HM400-2 57
Failure code [DGR6KX] Steering oil temperature out of range 1

Action code Failure code Steering oil temperature out of range
Trouble
E01 DGR6KX (Transmission controller system)
• Voltage in steering oil temperature sensor signal circuit is below 0.97 V (above 150°C).
Contents of • While voltage in torque converter oil temperature sensor and brake oil temperature sensor is below
trouble 3.75 V (above 55°C), voltage in transmission oil temperature sensor signal circuit is above 4.56 V
(below 15°C).
Action of
controller
Problem that
appears on • Steering oil temperature gauge is not displayed normally.
machine
• Signal input from steering oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - STRG OIL TEMP - 32701)
information (Monitoring code: TRANSMISSION - STRG OIL TEMP - 32702)

Defective steering oil tem- Steering oil
1 perature sensor (Internal T04 (male) Resistance
temperature
defect)
25°C 37 – 50 kz
Between (1) – (2)
100°C 3.5 – 4.0 kz
2 Max. 1 z
– T04 (female) (2) tance
and standard
Min. 1 Mz
4
Voltage Max. 5 V
– T04 (female) (1)
Defective transmission con- Steering oil
5 ATC1 (female) Resistance
troller temperature
25°C 37 – 50 kz
Between (14) – (21)
100°C 3.5 – 4.0 kz
58 HM400-2
Circuit diagram related to steering oil temperature sensor
HM400-2 59

© 2009 KOMATSU
All Rights Reserved
60 HM400-2
SEN01113-01
HM400-2

HM400-2 2001 and up
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system ............................... 4
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure
sensor system............................................................................................................................................ 6
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor ........................................................ 8
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system..................................... 10
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system...................................... 12
Failure code [DJF1KA] Disconnection in fuel level sensor system ............................................................... 14
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS................................................. 16
Failure code [DK52KX] Trouble in dump lever potentiometer 1.................................................................... 18
Failure code [DK53L8] Trouble in dump lever potentiometer 2..................................................................... 20
Failure code [DK54KX] Trouble in dump positioner sensor .......................................................................... 22
Failure code [DKH0KX] Pitch angle sensor signal out of range.................................................................... 24
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system............................. 26
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor.................................................... 27
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system................. 28
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system................. 29
HM400-2 1
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system............................. 30

Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system........................... 31
Failure code [DV00KB] Short circuit in buzzer output circuit......................................................................... 32
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output system........... 34
Failure code [DW73KZ] Trouble in dump selector valve output system........................................................ 36
Failure code [DW78KZ] Trouble in rear wheel BCV command output system.............................................. 38
Failure code [DW79KZ] Trouble in front wheel BCV command output system............................................. 40
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 ................... 42
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure
reducing valve .......................................................................................................................................... 44
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure
reducing valve .......................................................................................................................................... 46
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure
reducing valve .......................................................................................................................................... 48
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 .................. 50
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1 .................. 52
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure
reducing valve .......................................................................................................................................... 54
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure
reducing valve .......................................................................................................................................... 56
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure
reducing valve .......................................................................................................................................... 58
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2 ................. 60
2 HM400-2
HM400-2 3
Failure code [DGT1KX] Short circuit in torque converter oil temperature

sensor system 1
Action code Failure code Short circuit in torque converter oil temperature sensor system
Trouble
E01 DGT1KX (Transmission controller system)
• Voltage in torque converter oil temperature sensor signal circuit is below 0.97 V (above 150°C).
Contents of
• While voltage in transmission oil temperature sensor is below 0.37 V (above 55°C), voltage in
trouble
torque converter oil temperature sensor signal circuit is above 4.56 V (below 15°C).
Action of
• Fixes torque converter oil temperature.
controller
Problem that
appears on • Torque converter oil temperature gauge is not displayed normally.
machine
• Signal input from torque converter oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - T/C OIL TEMP - 30100)
information (Monitoring code: TRANSMISSION - T/C OIL TEMP - 30101)

Defective torque converter Torque converter oil
1 oil temperature sensor (Inter- CN23 (male) Resistance
temperature
nal defect)
25°C 37 – 50 kz
Between (1) – (2)
100°C 3.5 – 4.0 kz
2 Max. 1 z
and standard
Min. 1 Mz
4 24 V circuit) in wiring har-
ness Wiring harness between ATC1 (female) (9)
Voltage Max. 1 V
Defective transmission con- Torque converter oil
5 ATC1 (female) Resistance
troller temperature
25°C 37 – 50 kz
Between (9) – (21)
100°C 3.5 – 4.0 kz
4 HM400-2
Circuit diagram related to torque converter oil temperature sensor
HM400-2 5
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in

torque converter oil pressure sensor system 1
Action code Failure code Disconnection, ground fault, or short circuit in torque converter oil
Trouble pressure sensor system
E01 DHT5KX (Transmission controller system)
Contents of
• Voltage in torque converter oil pressure sensor signal circuit is below 0.5 V or above 4.5 V.
trouble
Action of
• Fixes torque converter oil pressure to oil pressure set in controller and continues control.
controller
Problem that
appears on • Large shock is made when lockup system operates.
machine
• Signal input from torque converter oil pressure sensor can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - T/C OIL PRESS - 32600)
information (Monitoring code: TRANSMISSION - T/C OIL PERSS - 32605)

CN22 (male) Voltage
Defective torque converter
Between (2) – (1) Power source 20 – 30 V
1 oil pressure sensor (Internal
defect) Between (3) – (1) Signal 0.8 – 2.0 V
Max. 1 z
ness (Disconnection in wiring – CN22 (female) (3) tance
2
nector) Max. 1 z
Possible causes Wiring harness between ATC1 (female) (8) Resis-
Max. 1 z
and standard – CN22 (female) (2) tance
circuit)
Min. 1 Mz
Voltage 0.8 – 2.0 V
ATC1, ATC3 Voltage
troller Power source 20 – 30 V
ATC1 (21)
Between ATC1 (19) –
Signal 0.8 – 2.0 V
(21)
6 HM400-2
Circuit diagram related to torque converter oil pressure sensor
HM400-2 7
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor 1

Action code Failure code Trouble in torque converter oil pressure sensor
Trouble
E01 DHT5L6 (Transmission controller system)
Contents of • While engine is stopped, signal circuit of torque converter oil pressure sensor inputted oil pressure
trouble signal.
Action of • Fixes torque converter oil pressure to oil pressure set in controller and continues control after
controller engine is started.
Problem that
appears on • Large shock is made when lockup system operates.
machine
• Signal input from torque converter oil pressure sensor can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - T/C OIL PRESS - 32600)
information (Monitoring code: TRANSMISSION - T/C OIL PERSS - 32605)

CN22 Voltage
Defective torque converter
1 oil pressure sensor (Internal
defect) Between (3) – (1) Signal 0.8 – 2.0 V
Possible causes troller, too, for another cause of trouble, and then judge.
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Hot short (Short circuit with and carry out troubleshooting.
state 2 24 V circuit) in wiring har-
Voltage 0.8 – 2.0 V
ATC1, ATC3 Voltage
troller Power source 20 – 30 V
ATC1 (21)
Between ATC1 (19) –
Signal 0.8 – 2.0 V
(21)
8 HM400-2
Circuit diagram related to torque converter oil pressure sensor
HM400-2 9
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor

(front) system 1
Action code Failure code Trouble in accumulator oil pressure sensor (front) system
Trouble
E01 DHU2KX (Retarder controller system)
Contents of
• Voltage in accumulator oil pressure sensor (front) signal circuit is below 0.5 V or above 4.5 V.
trouble
Action of
controller
Problem that
machine
• Signal input from pressure sensor can be checked with monitoring function.
Related (Monitoring code: BRAKE - ACC OIL PRE F - 35500)
information (Monitoring code: BRAKE - ACC OIL PER F - 35506)

B25 (male) Brake oil pressure Resistance
Below 4.9 MPa
Min. 1 Mz
{50 kg/cm²}
Between (B) – (A)
Above 4.9 MPa
Max. 1 z
Defective accumulator oil {50 kg/cm²}
1 pressure sensor (front) a Prepare with starting switch OFF, then turn starting switch ON
(Internal defect) and carry out troubleshooting.
B25 Voltage
Between (B) – (A) Power source 20 – 30 V
Between (C) – (A) Signal 1.8 – 3.5 V
Accordingly, if voltage is abnormal, check wiring harness and
Possible causes controller, too, for another cause of trouble, and then judge.
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state
Disconnection in wiring har- Wiring harness between BRC1 (female) (7) Resis-
Max. 1 z
ness (Disconnection in wiring – B25 (female) (C) tance
2
or defective contact in con- Wiring harness between BRC1 (female) Resis-
nector) Max. 1 z
(21) – B25 (female) (A) tance
Max. 1 z
(16) – B25 (female) (B) tance
Wiring harness between BRC1 (female) (7) Resis-
– B25 (female) (C) tance
circuit)
Min. 1 Mz
ness Wiring harness between BRC1 (female) (7)
Voltage Max. 1 V
– B25 (female) (C)
10 HM400-2
value in normal 5 Defective retarder controller BRC1 Voltage
state Between (16) – (21) Power source 20 – 30 V
Between (7) – (21) Signal 0.5 – 4.5 V
Circuit diagram related to accumulator oil pressure sensor (front)
HM400-2 11
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor

(rear) system 1
Action code Failure code Trouble in accumulator oil pressure sensor (rear) system
Trouble
E01 DHU3KX (Retarder controller system)
Contents of
• Voltage in accumulator oil pressure sensor (rear) signal circuit is below 0.5 V or above 4.5 V.
trouble
Action of
controller
Problem that
machine
• Signal input from pressure sensor can be checked with monitoring function.
Related (Monitoring code: BRAKE - ACC OIL PRE R - 35501)
information (Monitoring code: BRAKE - ACC OIL PER R - 35507)

B24 (male) Brake oil pressure Resistance
Below 4.9 MPa
Min. 1 Mz
{50 kg/cm²}
Between (B) – (A)
Above 4.9 MPa
Max. 1 z
Defective accumulator oil {50 kg/cm²}
1 pressure sensor (rear) (Inter- a Prepare with starting switch OFF, then turn starting switch ON
nal defect) and carry out troubleshooting.
B24 Voltage
Between (B) – (A) Power source 20 – 30 V
Between (C) – (A) Signal 1.8 – 3.5 V
Possible causes troller, too, for another cause of trouble, and then judge.
state
Disconnection in wiring har- Wiring harness between BRC1 (female) (7) Resis-
Max. 1 z
ness (Disconnection in wiring – B24 (female) (C) tance
2
nector) Max. 1 z
(21) – B24 (female) (A) tance
Max. 1 z
Wiring harness between BRC1 (female) (1) Resis-
– B24 (female) (C) tance
circuit)
Min. 1 Mz
ness Wiring harness between BRC1 (female) (1)
Voltage Max. 1 V
– B24 (female) (C)
12 HM400-2
value in normal 5 Defective retarder controller BRC1 Voltage
state Between (16) – (21) Power source 20 – 30 V
Between (1) – (21) Signal 0.5 – 4.5 V
Circuit diagram related to accumulator oil pressure sensor (rear)
HM400-2 13
Failure code [DJF1KA] Disconnection in fuel level sensor system 1

Action code Failure code Disconnection in fuel level sensor system
Trouble
E01 DJF1KA (Machine monitor system)
Contents of
• Voltage in fuel level sensor signal circuit is above 4.0 V.
trouble
Action of
machine monitor
Problem that
appears on • Fuel level gauge is not displayed normally.
machine
• Signal input from fuel level sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04200)
information (Monitoring code: MONITOR PANEL - FUEL SENSOR - 04201)

Defective fuel level sensor M06 (male) Fuel level Resistance
1
(Internal defect)
Full Approx. 10 z
Between (1) – (2)
Empty Approx. 80 z
ness (Disconnection in wiring Wiring harness between DPC3B (female) Resis-
value in normal Wiring harness between DPC3B (female) Resis-
Max. 1 z
state (6) – M06 (female) (2) tance
ness Wiring harness between DPC3B (female)
Voltage Max. 1 V
(3) – M06 (female) (1)
4 Defective machine monitor DPC3B (female) Fuel level Resistance
Full Approx. 10 z
Between (3) – (6)
Empty Approx. 80 z
14 HM400-2
Circuit diagram related to fuel level sensor

HM400-2 15
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS1

Action code Failure code Trouble in manual retarder potentiometer and RVS
Trouble
E03 DK51L5 (Retarder controller system)
Contents of
• Signal voltage in retarder control lever circuit potentiometer is below 0.3 V or above 4.7 V.
trouble
Takes following measures, depending on condition of trouble.
Action of • Controls with potentiometer signal.
controller • Limits output to solenoid to 70 %.
• Turns output to solenoid OFF.
Following occur, depending on remedy.
Problem that
• There is no particular effect on machine.
appears on
• Retarder cannot be controlled finely.
machine
• Retarder does not operate (Food brake operates, however).
• Signal from retarder control lever can be checked with monitoring function.
Related
(Monitoring code: BRAKE - RETARD LEVER - 33900)
information

RTL (male) Lever position Resistance
Defective body positioner
1 sensor potentiometer (Inter- Release Max. 1 z
Between (4) – (6)
nal defect) Apply Min. 1 Mz
Release Min. 1 Mz
Between (5) – (6)
Apply Max. 1 z
2 Defective resistor (RE1)
Resis-
Between RE1 (1) – (2) 250 ± 5 z
tance
Max. 1 z
(22) – RE1 (female) (2) tance
Possible causes
Wiring harness between RE1 (female) (1) – Resis-
BTL (female) (1) tance
value in normal
state Disconnection in wiring har- Wiring harness between BRC1 (female) Resis-
Max. 1 z
ness (Disconnection in wiring (21) – RTL (female) (3) tance
3
nector) Max. 1 z
(14) – BTL (female) (2) tance
Max. 1 z
(24) – RTL (female) (4) tance
Max. 1 z
Max. 1 z
(22) – RE1 (female) (2) tance
circuit) Wiring harness between RE1 (female) (1) – Resis-
Min. 1 Mz
BTL (female) (1) tance
Min. 1 Mz
(14) – BTL (female) (2) tance
16 HM400-2

Wiring harness between BRC1 (female)
Hot short (Short circuit with Voltage Max. 1 V
(22) – RE1 (female) (2)
ness Wiring harness between RE1 (female) (1) –
Voltage Max. 1 V
BTL (female) (1)
Voltage Max. 1 V
(14) – BTL (female) (2)
and standard
value in normal BRC1 Voltage
state
Between (22) – (21) 4.1 – 4.8 V
Between (14) – (21) 0.3 – 4.7 V
6 Defective retarder controller ing without turning starting switch ON.
BRC1 (female) Lever position Resistance
Between (24) – Release Max. 1 z
chassis ground Apply Min. 1 Mz
Between (18) – Release Min. 1 Mz
chassis ground Apply Max. 1 z
Circuit diagram related to body positioner
HM400-2 17
Failure code [DK52KX] Trouble in dump lever potentiometer 1 1

Action code Failure code Trouble in dump lever potentiometer 1
Trouble
E03 DK52KX (Transmission controller system)
Contents of
• Signal voltage in signal circuit of dump lever potentiometer 1 or 2 is below 0.3 V or above 4.7 V.
trouble
Action of • Operates normally with signal of normal potentiometer (A).
controller • Recognizes that dump lever is in HOLD position (B).
Problem that
• There is no particular effect on machine in case of (A) above.
appears on
• Dump body does not operate in case of (B) above.
machine
• Signal from dump lever can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - DUMP LEVER 1 - 34506)
information (Monitoring code: TRANSMISSION - DUMP LEVER 2 - 34507)

HSL Voltage
Between (4) – (1) Power source 4.6 – 5.4 V
Defective dump lever (Inter-
1 Between (2) – (1) Signal 1 0.3 – 4.7 V
nal defect)
Between (3) – (1) Signal 2 0.3 – 4.7 V
Max. 1 z
Disconnection in wiring har- – HSL (female) (4) tance
2 Max. 1 z
or defective contact in con- – HSL (female) (2) tance
Possible causes nector) Wiring harness between ATC1 (female) (7) Resis-
– HSL (female) (3) tance
value in normal
state Max. 1 z
Min. 1 Mz
Min. 1 Mz
Hot short (Short circuit with Voltage Max. 1 V
– HSL (female) (4)
Voltage Max. 1 V
Voltage Max. 1 V
18 HM400-2

and standard ATC1 Voltage
5
state troller Between (22) – (21) Power source 4.6 – 5.4 V
Between (1) – (21) Signal 1 0.3 – 4.7 V
Between (7) – (21) Signal 2 0.3 – 4.7 V
Circuit diagram related to dump lever potentiometer
HM400-2 19
Failure code [DK53L8] Trouble in dump lever potentiometer 2 1

Action code Failure code Trouble in dump lever potentiometer 2
Trouble
E03 DK53L8 (Transmission controller system)
Contents of
• Total voltage in signal circuit of dump lever potentiometer 1 or 2 is below 4.4 V or above 5.6 V.
trouble
Action of
• Recognizes that dump lever is in HOLD position.
controller
Problem that
appears on • Dump body does not operate.
machine
• Signal from dump lever can be checked with monitoring function.
(Monitoring code: TRANSMISSION - DUMP LEVER 1 - 34506)
Related
(Monitoring code: TRANSMISSION - DUMP LEVER 2 - 34507)
information
• If failure code [DK52KX] is displayed, carry out troubleshooting for it.

Possible causes Defective dump lever (Inter- HSL Voltage

1
and standard nal defect) Between (4) – (1) Power source 4.6 – 5.4 V
value in normal Between (2) – (1) Signal 1 0.3 – 4.7 V
state
Between (3) – (1) Signal 2 0.3 – 4.7 V
If cause 1 is not detected, transmission controller may be defec-
troller
out.)
20 HM400-2
Circuit diagram related to dump lever potentiometer
HM400-2 21
Failure code [DK54KX] Trouble in dump positioner sensor 1

Action code Failure code Trouble in dump positioner sensor
Trouble
E03 DK54KX (Transmission controller system)
Contents of
• Voltage in dump positioner sensor is below 0.3 V or above 4.7 V.
trouble
Action of • Controls dump body according to signal of dump lever.
controller • Recognizes that dump body is not seated.
• Seating shock of dump body increases.
Problem that
• Dump lever positioner does not function.
appears on
• Highest gear speed is limited.
machine
• Machine cannot travel in reverse when dump lever is not in FLOAT position.
• Signal from body positioner sensor can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - BODY POSITION - 34603)
information

T14 Voltage
Defective body positioner Between (C) – (A) Power source 4.6 – 5.4 V
1
sensor (Internal defect) Between (B) – (A) Signal 0.3 – 4.7 V
Max. 1 z
ness (Disconnection in wiring – T14 (female) (C) tance
2
nector) Max. 1 z
– T14 (female) (B) tance
Possible causes Wiring harness between ATC1 (female) (21) Resis-
Max. 1 z
and standard – T14 (female) (A) tance
– T14 (female) (C) tance
circuit)
Min. 1 Mz
Hot short (Short circuit with
4 24 V circuit) in wiring har- Voltage Max. 1 V
– T14 (female) (C)
ness
Voltage Max. 1 V
– T14 (female) (B)
Defective transmission con- ATC1 Voltage
5
troller
Between (22) – (21) Power source 4.6 – 5.4 V
Between (2) – (21) Signal 0.3 – 4.7 V
22 HM400-2
Circuit diagram related to body positioner sensor
HM400-2 23
Failure code [DKH0KX] Pitch angle sensor signal out of range 1

Action code Failure code Pitch angle sensor signal out of range
Trouble
E01 DKH0KX (Transmission controller system)
Contents of
• Voltage in pitch angle sensor is below 0.5 V or above 4.5 V.
trouble
Action of
controller
Problem that
appears on • Pitch angle cannot be sensed.
machine
• Signal from pitch angle sensor can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - ANGLE SENSOR - 32900)
information (Monitoring code: TRANSMISSION - ANGLE SENSOR - 32902)

T10 Voltage
Defective pitch angle sensor Between (C) – (A) Power source 20 – 30 V
1
(Internal defect) Between (B) – (A) Signal 0.5 – 4.5 V
Max. 1 z
ness (Disconnection in wiring – T10 (female) (B) tance
2
nector) Max. 1 z
Possible causes – T10 (female) (C) tance
and standard Wiring harness between ATC1 (female) (21) Resis-
Max. 1 z
value in normal – T10 (female) (A) tance
circuit)
Min. 1 Mz
– T10 (female) (C) tance
Voltage Max. 1 V
5
troller
Between (13) – (21) Signal 0.5 – 4.5 V
24 HM400-2
Circuit diagram related to pitch angle sensor
HM400-2 25
Failure code [DLF1KA] Disconnection in transmission input shaft speed

sensor system 1
Action code Failure code Disconnection in transmission input shaft speed sensor system
Trouble
E03 DLF1KA (Transmission controller system)
Contents of
• There is disconnection in transmission input shaft speed sensor signal circuit and signal is not input.
trouble
controller • If gearshift lever is set in N, gear speed is kept in neutral.
Problem that
• Lockup system is reset and gear cannot be shifted.
appears on
• If gearshift lever is set in N, machine cannot restart until it stops.
machine
• Signal from transmission input shaft speed sensor can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - TRANSMISSION SPEED: IN - 31200)
information

Defective adjustment of Transmission input shaft speed sensor may be adjusted defec-
1 transmission input shaft tively. Adjust it correctly, referring to Testing and adjusting, Adjust-
speed sensor ing transmission speed sensor.
Defective transmission input CN3 (male) Resistance
2
shaft speed sensor Between (1) – (2) 500 – 1,000 z
Possible causes Between (1), (2) – chassis
Min. 1 Mz
and standard ground
3 Max. 1 z
Max. 1 z
Defective transmission con- ing without turning starting switch ON.
4
troller ATC2 (female) Resistance
Between (40) – (39) 500 – 1,000 z
Circuit diagram related to transmission input shaft speed sensor
26 HM400-2
Failure code [DLF1LC] Trouble in transmission input shaft speed

sensor 1
Action code Failure code Trouble in transmission input shaft speed sensor
Trouble
E03 DLF1LC (Transmission controller system)
• Speed calculated from engine speed sensor signal, transmission intermediate shaft speed sensor
Contents of
signal, and transmission output shaft speed sensor signal is different from signal speed of transmis-
trouble
sion input shaft speed sensor.
Problem that
• Lockup system is reset and gear cannot be shifted.
appears on
• If gearshift lever is set in N, machine cannot restart until it stops.
machine
• Signal from transmission input shaft speed sensor can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - TRANSMISSION SPEED: IN - 31200)
information

1
Min. 1 Mz
ground
Possible causes Ground fault in wiring har- ing without turning starting switch ON.
and standard 2 ness (Short circuit with GND
value in normal circuit) Wiring harness between ATC2 (female) (40) Resis-
Min. 1 Mz
Voltage Max. 1 V
4
Between (40) – (39) 500 – 1,000 z
Circuit diagram related to transmission input shaft speed sensor
HM400-2 27
Failure code [DLF2KA] Disconnection in transmission intermediate

shaft speed sensor system 1
Action code Failure code Disconnection in transmission intermediate shaft speed sensor
Trouble system
Contents of • There is disconnection in transmission intermediate shaft speed sensor signal circuit and signal is
trouble not input.
Problem that
appears on
machine
• Signal from input shaft speed sensor can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - TRANSMISSION SPEED: MID - 31300)
information
• Method of reproducing failure code: Start engine + travel.

Defective adjustment of Transmission intermediate shaft speed sensor may be adjusted
1 transmission intermediate defectively. Adjust it correctly, referring to Testing and adjusting,
shaft speed sensor Adjusting transmission speed sensor.
2
Min. 1 Mz
and standard ground
ness (Disconnection in wiring Wiring harness between ATC2 (female) (20)
3 Voltage Max. 1 z
or defective contact in con- – CN4 (female) (1)
nector) Wiring harness between ATC2 (female) (39)
Voltage Max. 1 z
4
Between (20) – (39) 500 – 1,000 z
Circuit diagram related to transmission intermediate shaft speed sensor
28 HM400-2
Failure code [DLF2LC] Disconnection in transmission intermediate

shaft speed sensor system 1
Action code Failure code Disconnection in transmission intermediate shaft speed sensor
Trouble system
E03 DLF2LC (Transmission controller system)
• Speed calculated from engine speed sensor signal, transmission input shaft speed sensor signal,
Contents of
and transmission output shaft speed sensor signal is different from signal speed of transmission
trouble
intermediate shaft speed sensor.
Problem that
appears on
machine
• Signal from intermediate shaft speed sensor can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - TRANSMISSION SPEED: MID - 31300)
information

Defective transmission inter- CN4 (male) Resistance
1
mediate shaft speed sensor Between (1) – (2) 500 – 1,000 z
Min. 1 Mz
ground
Possible causes Ground fault in wiring har- ing without turning starting switch ON.
and standard 2 ness (Short circuit with GND
value in normal circuit) Wiring harness between ATC2 (female) (20) Resis-
Min. 1 Mz
Voltage Max. 1 V
4
Between (20) – (39) 500 – 1,000 z
Circuit diagram related to transmission intermediate shaft speed sensor
HM400-2 29
Failure code [DLF4KA] Disconnection in transmission differential speed

sensor system 1
Action code Failure code Disconnection in transmission differential speed sensor system
Trouble
Contents of
• There is disconnection in transmission differential speed sensor signal circuit and signal is not input.
trouble
Action of • Keeps interaxle differential lock OFF.
controller • Does not output neutral signal.
Problem that
machine
• Signal from transmission differential speed sensor can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - TRANSMISSION DIFF OUT - 31402)
information • Method of reproducing failure code: Start engine + Set interaxle differential lock switch to upper
position + travel.

Defective adjustment of Transmission differential speed sensor may be adjusted defec-
1 transmission differential tively. Adjust it correctly, referring to Testing and adjusting, Adjust-
Defective transmission input FE1 (male) Resistance
2
Min. 1 Mz
and standard ground
3 Max. 1 z
or defective contact in con- – FE1 (female) (1) tance
Max. 1 z
– FE1 (female) (2) tance
4
Between (10) – (29) 500 – 1,000 z
Circuit diagram related to transmission differential speed sensor
30 HM400-2
Failure code [DLT3KA] Disconnection in transmission output shaft

speed sensor system 1
Action code Failure code Disconnection in transmission output shaft speed sensor system
Trouble
E03 DLT3KA (Transmission controller system)
Contents of • There is disconnection in transmission output shaft speed sensor signal circuit and signal is not
trouble input.
Problem that • Lockup system is reset and gear cannot be shifted.
appears on • If gearshift lever is set in N, gear is set in neutral. (For emergency escape method, see Testing and
machine adjusting, Emergency escape method when electrical system has trouble.
• Signal from output shaft speed sensor can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - TRANSMISSION DIFF OUT - 31402)
information

Defective adjustment of Transmission output shaft speed sensor may be adjusted defec-
1 transmission output shaft tively. Adjust it correctly, referring to Testing and adjusting, Adjust-
Defective transmission out- CN5 (male) Resistance
2
put shaft speed sensor Between (1) – (2) 500 – 1,000 z
Min. 1 Mz
and standard ground
3 Max. 1 z
Max. 1 z
4
Between (30) – (29) 500 – 1,000 z
Circuit diagram related to transmission output shaft speed sensor
HM400-2 31
Failure code [DV00KB] Short circuit in buzzer output circuit 1

Action code Failure code Short circuit in buzzer output circuit
Trouble
E01 DV00KB (Machine monitor system)
Contents of
• There is short circuit in alarm buzzer output circuit.
trouble
Action of
• Turns buzzer output circuit OFF.
machine monitor
Problem that
appears on • Alarm buzzer does not sound.
machine
• Buzzer operation signal can be checked with monitoring function.
Related
(Monitoring code: MONITOR PANEL - D-OUT-0--3 - 40925)
information

Hot short (Short circuit with and carry out troubleshooting (Carry out troubleshooting when
1 24 V circuit) in wiring har- buzzer stops).
ness Wiring harness between DPC1 (female)
Voltage Max. 5 V
(13) – BZ2 (female) (2)
Possible causes
state 2 Defective machine monitor DPC1 Buzzer Voltage
Between (13) – (9), ON Max. 1 V
(10) OFF 20 – 30 V
Defective alarm buzzer
(Internal defect)
carried out.)
32 HM400-2
Circuit diagram related to alarm buzzer

HM400-2 33
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in

kick-out solenoid output system 1
Action code Failure code Trouble (Disconnection or ground fault) in kick-out solenoid output
Trouble system
E01 DW72KZ (Transmission controller system)
• When output to dump lever kick-out solenoid circuit is turned ON, more current flows.
Contents of
• When output to dump lever kick-out solenoid circuit is turned ON, no current flows.
trouble
• When output to dump lever kick-out solenoid circuit is turned OFF, some current flows.
Action of
• Turns output to dump lever kick-out solenoid OFF.
controller
Problem that
appears on • Dump lever detent lock does not work.
machine
• Operation signal of dump lever kick-out solenoid can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - D-OUT-0------7 - 40949)
information
• Method of reproducing failure code: Start engine + Operate dump lever to raise body.

Defective dump lever kick- LK0 (male) Resistance
1
out solenoid (Internal defect) Between (1) – (2) 39 z ± 5 %
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between ATC (female) (3) – Resis-
2 Max. 1 z
or defective contact in con- LK0 (female) (2) tance
Max. 1 z
– LK0 (female) (1) tance
Possible causes
and standard
value in normal Ground fault in wiring har-
state Wiring harness between ATC (female) (3) – Resis-
LK0 (female) (2) tance
circuit)
Min. 1 Mz
– LK0 (female) (1) tance
Wiring harness between ATC (female) (3) –
LK0 (female) (2)
ness
Voltage Max. 1 V
– LK0 (female) (1)
5
Between (38) – chassis ground 39 z ± 5 %
34 HM400-2
Circuit diagram related to dump lever kick-out solenoid
HM400-2 35
Failure code [DW73KZ] Trouble in dump selector valve output system 1

Action code Failure code Trouble in dump selector valve output system
Trouble
E03 DW73KZ (Transmission controller system)
• When output to dump selector valve circuit is turned ON, more current flows.
Contents of
• When output to dump selector valve circuit is turned ON, no current flows.
trouble
• When output to dump selector valve circuit is turned OFF, some current flows.
Action of • Turns output to dump selector valve OFF.
controller • Turns output to dump EPC valve OFF.
Problem that
appears on • Dump body does not move.
machine
• Operation signal of dump selector valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - D-OUT-0------7 - 40949)
information
• Method of reproducing failure code: Start engine + Operate dump lever to lower body.

Defective dump selector T01 (male) Resistance
1
valve (Internal defect) Between (A) – (B) 15 – 35 z
Between (A), (B) – chassis
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between ATC (female) (3) – Resis-
2 Max. 1 z
or defective contact in con- T01 (female) (B) tance
Max. 1 z
– T01 (female) (A) tance
Possible causes
and standard
state Wiring harness between ATC (female) (17) Resis-
– T01 (female) (A) tance
circuit)
Min. 1 Mz
Wiring harness between ATC (female) (17)
– T01 (female) (A)
ness
Voltage Max. 1 V
5
Between (17) – (3) 15 – 35 z
36 HM400-2
Circuit diagram related to dump selector valve
HM400-2 37
Failure code [DW78KZ] Trouble in rear wheel BCV command output

system 1
Action code Failure code Trouble in rear wheel BCV command output system
Trouble
E01 DW78KZ (Retarder controller system)
Contents of
• No current or excessive current flows in solenoid of brake cooling oil control valve (rear).
trouble
Action of
• Continues control.
controller
Problem that
appears on • Retarder may overheat since cooling capacity lowers.
machine
Related
• Method of reproducing failure code: Start engine + operate retarder control lever.
information

Defective solenoid of brake B06 (male) Resistance
1 cooling oil control valve
(rear) (Internal defect) Between (1) – (2) Approx. 40 z
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between BRC3 (female) Resis-
2 Max. 1 z
or defective contact in con- (37) – B06 (female) (1) tance
nector) Wiring harness between BRC3 (female) Resis-
Max. 1 z
state 3 ness (Short circuit with GND Min. 1 Mz
circuit)
Min. 1 Mz
(37) – B06 (female) (1)
ness
Voltage Max. 1 V
(13) – B06 (female) (2)
5 Defective retarder controller BRC3 (female) Solenoid Voltage
ON 20 – 30 V
Between (37) – (13)
OFF Max. 1 V
38 HM400-2
Circuit diagram related to brake cooling oil control valve (rear) solenoid
HM400-2 39
Failure code [DW79KZ] Trouble in front wheel BCV command output

system 1
Action code Failure code Trouble in front wheel BCV command output system
Trouble
E01 DW79KZ (Retarder controller system)
Contents of
• No current or excessive current flows in solenoid of brake cooling oil control valve (front).
trouble
Action of
controller
Problem that
appears on • Retarder may overheat since cooling capacity lowers.
machine
Related
• Method of reproducing failure code: Start engine + operate retarder control lever.
information

Defective solenoid of brake B07 (male) Resistance
1 cooling oil control valve
(front) (Internal defect) Between (1) – (2) Approx. 40 z
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
state 3 ness (Short circuit with GND Min. 1 Mz
circuit)
Min. 1 Mz
(27) – B07 (female) (1)
ness
Voltage Max. 1 V
(23) – B07 (female) (2)
5 Defective retarder controller BRC3 (female) Solenoid Voltage
ON 20 – 30 V
Between (27) – (23)
OFF Max. 1 V
40 HM400-2
Circuit diagram related to brake cooling oil control valve (front) solenoid
HM400-2 41
Failure code [DX11K4] Trouble in rear wheel proportional solenoid

pressure reducing valve 1 1
Action code Failure code Trouble in rear wheel proportional solenoid pressure reducing
Trouble valve 1
E03 DX11K4 (Retarder controller system)
Contents of • When output to retarder proportional pressure reducing valve (rear) is turned OFF, signal from
trouble retarder oil pressure switch (rear) is kept ON.
Action of • Continues control of retarder control lever.
controller • Continues control of overrun prevention retarder and accelerator-linked retarder.
Problem that • If solenoid is defective, rear brake drags.
appears on • If switch is defective or switch circuit has ground fault, gear is difficult to shift up and easy to shift
machine down.
• Condition of retarder oil pressure switch can be checked with monitoring function.
Related
(Monitoring code: BRAKE - D-IN--0------7 - 40932)
information
• Method of reproducing failure code: Start engine + operate retarder control lever to apply brake.

Defective retarder oil pres- Retarder control
1 sure switch (rear) (Internal B23 (male) Resistance
lever
defect)
Brake Max. 1 z
Between (1) – (2)
Release Min. 1 Mz
Possible causes circuit) Wiring harness between BRC1 (female) (5) Resis-
Min. 1 Mz
and standard – B23 (female) (1) tance
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Retarder control
BRC1, BRC3 Voltage
3 Defective retarder controller lever
Between BRC1 (5) – Brake Max. 1 V
BRC3 (21), (31),
(32), (33) Release 8 – 30 V
Defective rear brake circuit

If causes 1 – 3 are not detected, rear brake circuit or hydraulic and
or hydraulic and mechanical
mechanical system of retarder proportional pressure reducing
4 system of retarder propor-
valve (rear) may be defective. Carry out troubleshooting for
tional pressure reducing
hydraulic and mechanical system.
valve (rear)
42 HM400-2
Circuit diagram related to retarder oil pressure switch (rear)
HM400-2 43
Failure code [DX11KA] Disconnection in output circuit of rear wheel

proportional solenoid pressure reducing valve 1
Action code Failure code Disconnection in output circuit of rear wheel proportional solenoid
Trouble pressure reducing valve
E03 DX11KA (Retarder controller system)
Contents of • When signal is output to retarder proportional pressure reducing valve (rear) circuit, no current
trouble flows.
Problem that
appears on • Retarder (Rear brake) does not operate normally.
machine
Related
information

Defective retarder propor- B18 (male) Resistance
1 tional pressure reducing
valve (rear) (Internal defect) Between (1) – (2) 10 – 30 z
Min. 1 Mz
ground
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between BRC3 (female) Resis-
2 Max. 1 z
Max. 1 z
BRC3 (female) Resistance
Between (16) – (23) 10 – 30 z
44 HM400-2
Circuit diagram related to retarder proportional pressure reducing valve (rear)
HM400-2 45
Failure code [DX11KB] Ground fault in output circuit of rear wheel

Action code Failure code Ground fault in output circuit of rear wheel proportional solenoid
E03 DX11KB (Retarder controller system)
Contents of • When signal is output to retarder proportional pressure reducing valve (rear) circuit, more current
trouble flows.
• Turns output to retarder proportional pressure reducing valve (rear) OFF.
Action of
• Continues control of retarder control lever.
controller
• Continues control of overrun prevention retarder and accelerator-linked retarder.
Problem that
machine
Related
information

Min. 1 Mz
ground
Possible causes
and standard Wiring harness between BRC3 (female) Resis-
circuit) Min. 1 Mz
value in normal (16) – B18 (female) (1) tance
state
3 ness (with another wiring Wiring harness between BRC3 (female)
harness) Resis-
(16) – B18 (female) (1) and between BRC3 Min. 1 Mz
tance
(female) (16) – B19 (female) (1)
Between (16) – (23) 10 – 30 z
46 HM400-2
HM400-2 47
Failure code [DX11KY] Hot short in output circuit of rear wheel

Action code Failure code Hot short in output circuit of rear wheel proportional solenoid pres-
Trouble sure reducing valve
E03 DX11KY (Retarder controller system)
Contents of • When output to retarder proportional pressure reducing valve (rear) is turned OFF, some current
trouble flows.
Problem that
machine
Related
information

Min. 1 Mz
ground
and standard Hot short (Short circuit with
value in normal Wiring harness between BRC3 (female)
state (16) – B18 (female) (1)
ness
Voltage Max. 1 V
(23) – B18 (female) (2)
Retarder control
3 Defective retarder controller BRC3 (female) Voltage
lever
Brake Max. 1 V
Between (16) – (23)
Release 20 – 30 V
48 HM400-2
HM400-2 49
Failure code [DX11MA] Trouble in rear wheel proportional solenoid

Action code Failure code Trouble in rear wheel proportional solenoid pressure reducing
Trouble valve 2
E03 DX11MA (Retarder controller system)
Contents of • When signal is output to retarder proportional pressure reducing valve (rear) circuit, signal from
trouble retarder oil pressure switch (rear) is kept OFF.
Problem that
• If solenoid is defective, rear brake drags.
appears on
• If switch is defective or switch circuit has disconnection, condition does not change.
machine
• Output current to retarder proportional pressure reducing valve can be checked with monitoring
Related function.
information (Monitoring code: BRAKE - D-IN--0------7 - 40932)

1 sure switch (rear) (Internal B23 (male) Resistance
lever
defect)
Brake Max. 1 z
Between (1) – (2)
Release Min. 1 Mz
Defective retarder propor- Retarder control
2 tional pressure reducing B18 (male) Resistance
lever
valve (rear) (Internal defect)
Brake Max. 1 z
Between (1) – (2)
Possible causes Release Min. 1 Mz
and standard
value in normal Ground fault in wiring har- ing without turning starting switch ON.
Min. 1 Mz
– B23 (female) (1) tance
Retarder control
4 Defective retarder controller BRC3 Resistance
lever
Brake Max. 1 z
Between (16) – (23)
Release Min. 1 Mz
Defective rear brake circuit
If causes 1 – 4 are not detected, rear brake circuit or hydraulic and
valve (rear) may be defective. Carry out troubleshooting for
valve (rear)
1
50 HM400-2
HM400-2 51
Failure code [DX12K4] Trouble in front wheel proportional solenoid

Action code Failure code Trouble in front wheel proportional solenoid pressure reducing
Trouble valve 1
E03 DX12K4 (Retarder controller system)
Contents of • When output to retarder proportional pressure reducing valve (front) is turned OFF, signal from
trouble retarder oil pressure switch (front) is kept ON.
Problem that • If retarder proportional pressure reducing valve (front) is defective, front brake drags.
appears on • If sensor switch is defective or switch input circuit has ground fault, gear is difficult to shift up and
machine easy to shift down.
• Output current to retarder proportional pressure reducing valve (front) can be checked with monitor-
Related ing function.
information (Monitoring code: BRAKE - D-IN--0------7 - 40932)

1 sure switch (front) (Internal B16 (male) Resistance
lever
defect)
Brake Max. 1 z
Between (1) – (2)
Release Min. 1 Mz
Possible causes circuit) Wiring harness between BRC1 (female) (11) Resis-
Min. 1 Mz
and standard – B16 (female) (1) tance
Retarder control
BRC1, BRC3 Voltage
3 Defective retarder controller lever
Between BRC1 (11) Brake Max. 1 V
– BRC3 (21), (31),
(32), (33) Release 8 – 30 V
Defective front brake circuit

If causes 1 – 3 are not detected, front brake circuit or hydraulic and
valve (front) may be defective. Carry out troubleshooting for
valve (front)
52 HM400-2
Circuit diagram related to retarder oil pressure switch (front)
HM400-2 53
Failure code [DX12KA] Disconnection in output circuit of front wheel

Action code Failure code Disconnection in output circuit of front wheel proportional solenoid
E03 DX12KA (Retarder controller system)
Contents of • When signal is output to retarder proportional pressure reducing valve (front) circuit, no current
trouble flows.
Problem that
appears on • Retarder (Front brake) does not operate normally.
machine
ing function.
Related
(Monitoring code: BRAKE - BK OUTP DIR F - 33807)
information
(Monitoring code: TRANSMISSION - BK OUTP DIR F - 33807)

valve (front) (Internal defect) Between (1) – (2) 10 – 30 z
Min. 1 Mz
ground
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between BRC3 (female) (6) Resis-
2 Max. 1 z
or defective contact in con- – B19 (female) (1) tance
Max. 1 z
Between (6) – (13) 10 – 30 z
54 HM400-2
Circuit diagram related to retarder proportional pressure reducing valve (front)
HM400-2 55
Failure code [DX12KB] Ground fault in output circuit of front wheel

Action code Failure code Ground fault in output circuit of front wheel proportional solenoid
E03 DX12KB (Retarder controller system)
Contents of • When signal is output to retarder proportional pressure reducing valve (front) circuit, more current
trouble flows.
• Turns output to retarder proportional pressure reducing valve (front) OFF.
Action of
• Continues control of retarder control lever.
controller
• Continues control of overrun prevention retarder and accelerator-linked retarder.
Problem that
machine
ing function.
Related
information

Min. 1 Mz
ground
Possible causes
and standard Wiring harness between BRC3 (female) (6) Resis-
circuit) Min. 1 Mz
value in normal – B19 (female) (1) tance
state
3 ness (with another wiring Wiring harness between BRC3 (female) (6)
harness) Resis-
– B19 (female) (1) and between BRC3 Min. 1 Mz
tance
Between (6) – (13) 10 – 30 z
56 HM400-2
HM400-2 57
Failure code [DX12KY] Hot short in output circuit of front wheel

Action code Failure code Hot short in output circuit of front wheel proportional solenoid pres-
Trouble sure reducing valve
E03 DX12KY (Retarder controller system)
Contents of • When output to retarder proportional pressure reducing valve (front) is turned OFF, some current
trouble flows.
Problem that
machine
ing function.
Related
information

Min. 1 Mz
ground
and standard Hot short (Short circuit with
value in normal Wiring harness between BRC3 (female) (6)
state – B19 (female) (1)
ness
Voltage Max. 1 V
(13) – B19 (female) (2)
Retarder control
3 Defective retarder controller BRC3 (female) Voltage
lever
Brake Max. 1 V
Between (6) – (13)
Release 20 – 30 V
58 HM400-2
HM400-2 59
Failure code [DX12MA] Trouble in front wheel proportional solenoid

Action code Failure code Trouble in front wheel proportional solenoid pressure reducing
Trouble valve 2
E03 DX12MA (Retarder controller system)
Contents of • When signal is output to retarder proportional pressure reducing valve (front) circuit, signal from
trouble retarder oil pressure switch (front) is kept OFF.
Action of
controller
Problem that
• If solenoid is defective, front retarder cannot be used.
appears on
• If switch is defective or switch input circuit has disconnection, condition does not change.
machine
• Input signal of retarder oil pressure switch can be checked with monitoring function.
Related (Monitoring code: BRAKE - BK OUTP DIR F - 33807)
information (Monitoring code: TRANSMISSION - BK OUTP DIR F - 33807)

1 sure switch (front) (Internal B19 Voltage
lever
defect)
Brake Max. 1 V
Between (1) – (2)
Release 20 – 30 V
Defective retarder propor- Retarder control
2 tional pressure reducing B18 (male) Resistance
lever
valve (front) (Internal defect)
Brake Max. 1 z
Between (1) – (2)
Possible causes Release Min. 1 Mz
and standard
value in normal Ground fault in wiring har- ing without turning starting switch ON.
Min. 1 Mz
Retarder control
4 Defective retarder controller BRC3 Resistance
lever
Brake Max. 1 z
Between (6) – (13)
Release Min. 1 Mz
Defective front brake circuit
If causes 1 – 4 are not detected, front brake circuit or hydraulic and
valve (front) may be defective. Carry out troubleshooting for
valve (front)
1
60 HM400-2
Circuit diagram related to retarder oil pressure switch (front) and retarder proportional pressure
reducing valve (front)
HM400-2 61

© 2009 KOMATSU
All Rights Reserved
62 HM400-2
SEN01114-00
HM400-2

HM400-2 2001 and up
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve ........................................ 4
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve........................................... 6
Failure code [DX13KY] Hot short in output circuit of dump EPC valve ................................................ 8
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system ................... 10
Failure code [DX15KZ] Trouble in front wheel differential lock command output system .................. 12
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid . 14
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid.... 16
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid ......... 18
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid ............................. 19
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid................................ 20
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid ..................................... 22
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid .................................... 24
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve .................. 26
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve ....................... 28
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid ................................... 32
HM400-2 1
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve.................. 34
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve....................... 36
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid................................... 40
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve................. 42
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve ...................... 44
2 HM400-2

Failure code [DX13KA] Disconnection in output circuit of dump EPC
valve 1
Action code Failure code Disconnection in output circuit of dump EPC valve
Trouble
E03 DX13KA (Transmission controller system)
Contents of
• When signal is output to dump EPC valve circuit, no current flows.
trouble
Problem that
machine
• Output current to dump EPC valve can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - HOIST EPC DIR - 45601)
information • Method of reproducing failure code: Turn starting switch ON + operate dump lever to raise or lower
dump body.

Defective dump EPC valve T02 (male) Resistance
1
Min. 1 Mz
ground
Possible causes
and standard
value in normal
2 Max. 1 z
Max. 1 z
3
Between (28) – (9) 5 – 20 z
4 HM400-2
Circuit diagram related to dump EPC valve
HM400-2 5
Failure code [DX13KB] Ground fault in output circuit of dump EPC

valve 1
Action code Failure code Ground fault in output circuit of dump EPC valve
Trouble
E03 DX13KB (Transmission controller system)
Contents of
• When signal is output to dump EPC valve, more current flows.
trouble
Problem that
machine
Related (Monitoring code: TRANSMISSION - HOIST EPC DIR - 45601)
information • Method of reproducing failure code: Turn starting switch ON + operate dump lever to raise or lower
dump body.

Defective dump EPC valve T02 (male) Resistance
1
Min. 1 Mz
ground
Possible causes
and standard Wiring harness between ATC3 (female) (28) Resis-
circuit) Min. 1 Mz
value in normal – T02 (female) (1) tance
state
3 ness (with another wiring Wiring harness between ATC3 (female) (28)
harness) Resis-
– T02 (female) (1) and between ATC3 Min. 1 Mz
tance
(female) (9) – T02 (female) (2)
4
Between (28) – (9) 5 – 20 z
6 HM400-2
HM400-2 7
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 1
Action code Failure code Hot short in output circuit of dump EPC valve
Trouble
E03 DX13KY (Transmission controller system)
Contents of
• When output to dump EPC valve is turned OFF, some current flows.
trouble
Problem that
appears on
machine
Related
(Monitoring code: TRANSMISSION - HOIST EPC DIR - 45601)
information

Hot short (Short circuit with Wiring harness between ATC3 (female) (28)
Possible causes 1 Voltage Max. 1 V
24V circuit) in wiring harness – T02 (female) (1)
and standard
value in normal Voltage Max. 1 V
– T02 (female) (2)
state
Defective transmission con- and carry out troubleshooting.
2
troller ATC3 (female) Voltage
Between (28) – (3) Max. 1 V
8 HM400-2
Failure code [DX14KZ] Trouble in rear wheel differential lock command

output system 1
Action code Failure code Trouble in rear wheel differential lock command output system
Trouble
E03 DX14KZ (Retarder controller system)
• When output to rear differential lock solenoid circuit is turned ON, more current flows.
Contents of
• When output to rear differential lock solenoid circuit is turned ON, no current flows.
trouble
• When output to rear differential lock solenoid circuit is turned OFF, some current flows.
Action of
• Turns output to rear differential lock solenoid OFF.
controller
Problem that
appears on • Rear differential lock (center differential and rear differential) does not operate.
machine
• Operation of rear wheel differential lock can be checked with monitoring function.
Related (Monitoring code: BRAKE - D-OUT-0----7 - 40955)
information • Method of reproducing failure code: Turn starting switch ON + set right and left differential lock
switches to upper position + press right and left differential lock pedals.

Defective rear differential B36 (male) Resistance
1 lock solenoid (Internal
Min. 1 Mz
ground
2 Max. 1 z
Possible causes nector) Wiring harness between BRC3 (female) (3) Resis-
value in normal
state Ground fault in wiring har- ing without turning starting switch ON.
circuit) Wiring harness between BRC3 (female) Resis-
Min. 1 Mz
4 ness (with another wiring Wiring harness between BRC3 (female)
harness) Resis-
(17) – B36 (female) (1) and between BRC3 Min. 1 Mz
tance
5
24V circuit) in wiring harness Wiring harness between BRC3 (female)
Voltage Max. 1 V
(17) – B36 (female) (1)
10 HM400-2

and standard Between (17), (3) – chassis
value in normal Min. 1 Mz
6 Defective retarder controller ground
state
BRC3 (female) Voltage
Max. 1 V
ground
Circuit diagram related to rear differential lock solenoid
HM400-2 11
Failure code [DX15KZ] Trouble in front wheel differential lock command

output system 1
Action code Failure code Trouble in front wheel differential lock command output system
Trouble
E03 DX15KZ (Retarder controller system)
• When output to front differential lock solenoid circuit is turned ON, more current flows.
Contents of
• When output to front differential lock solenoid circuit is turned ON, no current flows.
trouble
• When output to front differential lock solenoid circuit is turned OFF, some current flows.
Action of
• Turns output to front differential lock solenoid OFF.
controller
Problem that
appears on • Front differential lock does not operate.
machine
• Operation of front wheel differential lock can be checked with monitoring function.
Related (Monitoring code: BRAKE - D-OUT-0----7 - 40955)
information • Method of reproducing failure code: Turn starting switch ON + set right and left differential lock
switches to upper position + press right and left differential lock pedals.

Defective front differential B35 (male) Resistance
1 lock solenoid (Internal
Min. 1 Mz
ground
ness (Disconnection in wiring Wiring harness between BRC3 (female) (7) Resis-
2 Max. 1 z
or defective contact in con- – B35 (female) (1) tance
Possible causes nector) Wiring harness between BRC3 (female) (3) Resis-
value in normal
state Ground fault in wiring har- ing without turning starting switch ON.
Min. 1 Mz
4 ness (with another wiring Wiring harness between BRC3 (female) (7)
harness) Resis-
– B35 (female) (1) and between BRC3 Min. 1 Mz
tance
5
24V circuit) in wiring harness Wiring harness between BRC3 (female) (7)
Voltage Max. 1 V
– B35 (female) (1)
12 HM400-2

and standard Between (7), (3) – chassis
value in normal Min. 1 Mz
6 Defective retarder controller ground
state
BRC3 (female) Voltage
Max. 1 V
ground
Circuit diagram related to front differential lock solenoid
HM400-2 13
Failure code [DXH0KA] Disconnection in output circuit of interaxle

differential lock clutch solenoid 1
Action code Failure code Disconnection in output circuit of interaxle differential lock clutch
Trouble solenoid
E01 DXH0KA (Transmission controller system)
Contents of
• When signal is output to differential lock clutch solenoid valve, no current flows.
trouble
Action of
• Continues outputting (Since no current flows, solenoid does not operate).
controller
Problem that
machine
• Output voltage to differential lock clutch solenoid valve can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - ECMV D DIR - 31607)
information • Method of reproducing failure code: Turn starting switch ON + set interaxle differential lock switch to
upper position.

Defective differential lock ing without turning starting switch ON.
1 clutch solenoid valve (Inter-
nal disconnection)
Between (1) – (2) 5 – 15 z
value in normal ness (Disconnection in wiring Wiring harness between ATC3 (female) (35) Resis-
2 Max. 1 z
state or defective contact in con- – CN20 (female) (1) tance
Max. 1 z
3
Between (35) – (23) 5 – 15 z
14 HM400-2
Circuit diagram related to differential lock clutch solenoid valve
HM400-2 15
Failure code [DXH0KB] Ground fault in output circuit of interaxle

Action code Failure code Ground fault in output circuit of interaxle differential lock clutch
Trouble solenoid
E01 DXH0KB (Transmission controller system)
Contents of • When signal is output to differential lock clutch solenoid valve, abnormally large current flows, or
trouble when signal is turned OFF, some current flows.
Action of
• Turns interaxle differential lock command OFF.
controller
Problem that
appears on • Interaxle differential lock does not operate or is not reset.
machine
upper position.

Defective differential lock CN20 (male) Resistance
1 clutch solenoid valve (Inter-
nal disconnection) Between (1) – (2) 5 – 15 z
Min. 1 Mz
ground
Possible causes circuit) Wiring harness between ATC3 (female) (35) Resis-
Min. 1 Mz
harness) Resis-
– CN20 (female) (1) and between ATC3 Min. 1 Mz
tance
(female) (23) – CN20 (female) (2)
Defective transmission con- ATC3 (female) Resistance
4
troller Between (35) – (23) 5 – 15 z
Min. 1 Mz
ground
16 HM400-2
HM400-2 17
Failure code [DXH0KY] Hot short in output circuit of interaxle

Action code Failure code Hot short in output circuit of interaxle differential lock clutch sole-
Trouble noid
E03 DXH0KY (Transmission controller system)
Contents of
• When output to differential lock clutch solenoid valve is turned OFF, some current flows.
trouble
Action of
• Turns output to interaxle differential lock clutch solenoid valve OFF.
controller
Problem that
appears on • Differential lock is kept ON.
machine
lower position.

1
Possible causes Voltage Max. 1 V
and standard
value in normal
state
2
troller Between (35) – (23) Max. 1 V
Max. 1 V
ground
18 HM400-2
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch

solenoid 1
Action code Failure code Disconnection in output circuit of lockup clutch solenoid
Trouble
Contents of
• When signal is output to lockup clutch solenoid, no current flows.
trouble
Action of
• Turns lockup operation OFF.
controller
Problem that
• Lockup system does not operate.
appears on
machine
• Output current to lockup solenoid can be checked with monitoring function.
Related
information
• Method of reproducing failure code: Start engine + travel at F1 + turn lockup lamp ON.

Defective lockup clutch sole- ing without turning starting switch ON.
1
noid (Internal defect) CN20 (male) Resistance
Between (1) – (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (6) – (23) 5 – 15 z
Circuit diagram related to lockup clutch solenoid valve
HM400-2 19
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch

solenoid 1
Action code Failure code Ground fault in output circuit of lockup clutch solenoid
Trouble
Contents of • When signal is output to lockup clutch solenoid, abnormally large current flows, or when signal is
trouble turned OFF, some current flows.
Problem that • Lockup system is kept OFF or ON.
appears on • If gearshift lever is set in "N", machine cannot restart until it stops (Machine cannot restart even after
machine it stops, depending on trouble condition).
Related
information
• Method of reproducing failure code: Start engine + travel at F1 + turn lockup lamp ON.

Defective lockup clutch sole- CN18 (male) Resistance
1
noid (Internal defect) Between (1) – (2) 5 – 15 z
Min. 1 Mz
ground
Min. 1 Mz
harness) Resis-
tance
4
Min. 1 Mz
ground
20 HM400-2
HM400-2 21
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid1
Action code Failure code Hot short in output circuit of lockup clutch solenoid
Trouble
Contents of
• When output to lockup clutch solenoid is turned OFF, some current flows.
trouble
Action of
• Keeps current gear speed and turns lockup system OFF.
controller
appears on • Lockup system is kept OFF.
machine • If gearshift lever is set in "N", machine cannot restart until it stops.
Related
information

1
and standard
value in normal
state
2
Min. 1 Mz
ground
22 HM400-2
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid1

Action code Failure code Disconnection in output circuit of Hi clutch solenoid
Trouble
Contents of
• When signal is output to Hi clutch ECMV solenoid valve, no current flows.
trouble
Problem that
machine
Related
information

Min. 1 Mz
ground
Possible causes
and standard
value in normal
2 Max. 1 z
Max. 1 z
3
Between (26) – (13) 5 – 15 z
24 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 25
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV

solenoid valve 1
Action code Failure code Ground fault in output circuit of Hi clutch ECMV solenoid valve
Trouble
Contents of • When signal is output to Hi clutch ECMV solenoid valve, abnormally large current flows, or when
trouble signal is turned OFF, some current flows.
Problem that
machine
Related
information

Min. 1 Mz
ground
Min. 1 Mz
harness) Resis-
tance
4
Min. 1 Mz
ground
26 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 27
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV

solenoid valve 1
Action code Failure code Hot short in output circuit of Hi clutch ECMV solenoid valve
Trouble
Contents of
• When output to Hi clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Problem that
machine
Related
information

1
and standard
value in normal
state
2
Min. 1 Mz
ground
28 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 29
30 HM400-2
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid1

Action code Failure code Disconnection in output circuit of Lo clutch solenoid
Trouble
Contents of
• When signal is output to Lo clutch ECMV solenoid valve, no current flows.
trouble
Problem that
machine
Related
information

Min. 1 Mz
ground
Possible causes
and standard
value in normal
2 Max. 1 z
Max. 1 z
3
Between (16) – (3) 5 – 15 z
32 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 33
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV

solenoid valve 1
Action code Failure code Ground fault in output circuit of Lo clutch ECMV solenoid valve
Trouble
Contents of • When signal is output to Lo clutch ECMV solenoid valve, abnormally large current flows, or when
Problem that
machine
Related
information

Min. 1 Mz
ground
Min. 1 Mz
harness) Resis-
tance
4
Min. 1 Mz
ground
34 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 35
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV

solenoid valve 1
Action code Failure code Hot short in output circuit of Lo clutch ECMV solenoid valve
Trouble
Contents of
• When output to Lo clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Problem that
machine
Related
information

1
and standard
value in normal
state
2
Min. 1 Mz
ground
36 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 37
38 HM400-2
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid1

Action code Failure code Disconnection in output circuit of 1st clutch solenoid
Trouble
Contents of
• When signal is output to 1st clutch ECMV solenoid valve, no current flows.
trouble
Problem that
machine
Related
information

Defective 1st clutch ECMV ing without turning starting switch ON.
defect)
Between (1) – (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (36) – (13) 5 – 15 z
40 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 41
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch

ECMV solenoid valve 1
Action code Failure code Ground fault in output circuit of 1st clutch ECMV solenoid valve
Trouble
Contents of • When signal is output to 1st clutch ECMV solenoid valve, abnormally large current flows, or when
Problem that
machine
Related
information

Min. 1 Mz
ground
Min. 1 Mz
harness) Resis-
tance
4
Min. 1 Mz
ground
42 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 43
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV
solenoid valve 1
Action code Failure code Hot short in output circuit of 1st clutch ECMV solenoid valve
Trouble
Contents of
• When output to 1st clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Problem that
machine
Related
information

Min. 1 Mz
ground
Possible causes
and standard
value in normal 2
state 24V circuit) in wiring harness Wiring harness between ATC3 (female) (36)
Voltage Max. 1 V
3
Min. 1 Mz
ground
44 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 45
46 HM400-2

© 2006 KOMATSU
All Rights Reserved
48 HM400-2
SEN01115-00
HM400-2

HM400-2 2001 and up
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid ................................... 2
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve ................. 4
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve....................... 6
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid .................................. 10
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve ................ 12
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve ..................... 14
Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid ........................... 18
Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve ......... 20
Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve............... 22
HM400-2 1

Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch
solenoid 1
Action code Failure code Disconnection in output circuit of 2nd clutch solenoid
Trouble
Contents of
• When signal is output to 2nd clutch ECMV solenoid valve, no current flows.
trouble
Problem that
machine
Related
information

Defective 2nd clutch ECMV ing without turning starting switch ON.
defect)
Between (1) – (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (5) – (3) 5 – 15 z
2 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 3
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch

Action code Failure code Ground fault in output circuit of 2nd clutch ECMV solenoid valve
Trouble
Contents of • When signal is output to 2nd clutch ECMV solenoid valve, abnormally large current flows, or when
Problem that
machine
Related
information

Defective 2nd clutch ECMV CN14 (male) Resistance
Min. 1 Mz
ground
Min. 1 Mz
harness) Resis-
tance
4
Min. 1 Mz
ground
4 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 5
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV
solenoid valve 1
Action code Failure code Hot short in output circuit of 2nd clutch ECMV solenoid valve
Trouble
Contents of
• When output to 2nd clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Problem that
machine
Related
information

1
and standard
value in normal
state
2
Min. 1 Mz
ground
6 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 7
8 HM400-2
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch

solenoid 1
Action code Failure code Disconnection in output circuit of 3rd clutch solenoid
Trouble
Contents of
• When signal is output to 3rd clutch ECMV solenoid valve, no current flows.
trouble
Problem that
machine
Related
information

Defective 3rd clutch ECMV ing without turning starting switch ON.
defect)
Between (1) – (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (15) – (23) 5 – 15 z
10 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 11
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch

Action code Failure code Ground fault in output circuit of 3rd clutch ECMV solenoid valve
Trouble
Contents of • When signal is output to 3rd clutch ECMV solenoid valve, abnormally large current flows, or when
Problem that
machine
Related
information

Defective 3rd clutch ECMV CN16 (male) Resistance
Min. 1 Mz
ground
Min. 1 Mz
harness) Resis-
tance
4
Min. 1 Mz
ground
12 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 13
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV
solenoid valve 1
Action code Failure code Hot short in output circuit of 3rd clutch ECMV solenoid valve
Trouble
Contents of
• When output to 3rd clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Problem that
machine
Related
information

1
and standard
value in normal
state
2
Min. 1 Mz
ground
14 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 15
16 HM400-2
Failure code [DXH7KA] Disconnection in output circuit of reverse clutch

solenoid 1
Action code Failure code Disconnection in output circuit of reverse clutch solenoid
Trouble
Contents of
• When signal is output to reverse clutch ECMV solenoid valve, no current flows.
trouble
Problem that
machine
Related
information

Defective reverse clutch ing without turning starting switch ON.
nal defect)
Between (1) – (2) 5 – 15 z
2 Max. 1 z
Max. 1 z
3
Between (25) – (13) 5 – 15 z
18 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 19
Failure code [DXH7KB] Ground fault in output circuit of reverse clutch

Action code Failure code Ground fault in output circuit of reverse clutch ECMV solenoid valve
Trouble
Contents of • When signal is output to reverse clutch ECMV solenoid valve, abnormally large current flows, or
trouble when signal is turned OFF, some current flows.
Problem that
machine
Related
information

Defective reverse clutch CN8 (male) Resistance
nal defect) Between (1) – (2) 5 – 15 z
Min. 1 Mz
ground
Min. 1 Mz
harness) Resis-
tance
4
Min. 1 Mz
ground
20 HM400-2
Table 1
Gear speed before
trouble
F6
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
R3
2nd 2nd 3R R3 OFF
R2
1st 1st 2R R2 OFF
R1
HM400-2 21
Failure code [DXH7KY] Hot short in output circuit of reverse clutch

Action code Failure code Hot short in output circuit of reverse clutch ECMV solenoid valve
Trouble
Contents of
• When output to reverse clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Problem that
machine
Related
information

1
and standard
value in normal
state
2
Min. 1 Mz
ground
22 HM400-2
Table 2
Gear speed
before trouble
2nd OFF NEUTRAL OFF
F6
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
F5
Hi 3H F6 OFF
3rd 3L F5 OFF
F4
Lo 3L F5 OFF
3rd 3L F5 OFF
F3
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
R3
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
R2
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Lo OFF NEUTRAL OFF
HM400-2 23
24 HM400-2

© 2006 KOMATSU
All Rights Reserved
26 HM400-2
SEN01116-01
HM400-2

HM400-2 2001 and up
Troubleshooting for electrical system
(E-mode)
Before troubleshooting for electrical system ................................................................................................... 3
Information in troubleshooting table................................................................................................................ 9
E-1 Engine does not start (Starting motor does not turn)............................................................................. 10
E-2 Auto preheater does not operate........................................................................................................... 14
E-3 When starting switch is turned ON, machine monitor displays nothing................................................. 18
E-4 When starting switch is turned OFF, machine monitor cannot be operated .......................................... 20
E-5 Alarm buzzer does not stop sounding ................................................................................................... 22
E-6 Machine monitor does not normally display gauges, caution lamps, and character display section..... 23
E-7 Display of character display section cannot be changed ...................................................................... 24
E-8 Power mode selection function does not operate normally................................................................... 28
E-9 AISS function does not operate normally .............................................................................................. 30
(Differential lock-up specification) ....................................................................................................... 32
E-11 Interaxle differential lock-up function does not operate normally......................................................... 36
HM400-2 1
E-12 Display of seat belt caution lamp is abnormal ..................................................................................... 38

E-13 Turn signal lamps and pilot lamps do not operate normally ................................................................ 40
E-14 Night lighting is abnormal .................................................................................................................... 45
E-15 Backup lamp and backup buzzer operate abnormally......................................................................... 51
E-16 Emergency steering system does not operate .................................................................................... 55
2 HM400-2
Before troubleshooting for electrical system 1

a This connection table shows the devices to which each power supply of the circuit breakers and fuse box
supplies power (An accessory power supply is a device which supplies power while the starting switch is
in the ON position and an unswitched power supply is a device which supplies power while the starting
switch is in the OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the circuit breakers
and fuses to see if the power is supplied normally.
Locations and connections of circuit breakers (30 A and 80 A)
Circuit breaker Circuit breaker

Type of power supply Destination of power
No. capacity
Fuse box (BT2)
Unswitched power 1 30A
Fuse box (BT4)
supply
Fuse box (BT1)
Accessory power
Fuse box (BT2)
supply 4 80A
Fuse box (BT3)
Fuse box (BT4)
HM400-2 3

Lamp switch circuit (including brightness control switch)
BT1-No. 3 power supply (through relay)
1 20A BT1-No. 4 power supply (through relay)
2 10A Flasher
3 20A Headlamp (High beam)
Accessory power
4 10A Headlamp (Low beam)
supply
5 10A Small lamp (Right)
6 10A Small lamp (Left)
7 10A Stop lamp (Right and left)
Backup lamp (Right and left)
8 20A
Backup buzzer
9 20A Front working lamp (Right and left)
4 HM400-2

11 10A Engine controller (Starting switch ACC signal)
12 10A KOMTRAX terminal
13 10A Machine monitor
Accessory power
14 10A Parking brake solenoid valve
supply
15 10A Rear view monitor
16 20A Front wiper motor
17 20A Rear wiper motor
Machine monitor
18 10A
KOMTRAX
20 20A Starting switch (Terminal B power supply)
Unswitched power 21 10A Transmission controller
supply 22 20A Hazard lamp (Front, rear, right, and left)
23 10A Emergency steering relay (motor circuit) and timer
Room lamp
24 10A
Car radio or car stereo
HM400-2 5

26 20A Fog lamp (Right and left)
28 10A Heater
29 10A Heater
Machine monitor
30 10A
Alarm buzzer
Accessory power Transmission controller
32 10A
supply Shift lever
33 10A Emergency steering relay (signal circuit) and timer
34 20A Power window motor (Right)
35 20A Power window motor (Left)
36 — (Spare)
37 — (Spare)
38 — (Spare)
39 30A Rear glass heater
Unswitched power
40 30A Engine controller
supply
6 HM400-2

41 10A Room lamp 2
Accessory power
supply
Unswitched power
supply
47 10A Tachograph
HM400-2 7
Location and connection of fuse (V)

Accessory power
V 300A Intake air heater
supply
8 HM400-2

a The following information is summarized in the troubleshooting table and the related electrical circuit dia-
gram. Before carrying out troubleshooting, understand that information fully.
Trouble Trouble which occurred in the machine

Related
information
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
<Precautions for troubleshooting>
state ence numbers, which do
(1) Method of indicating connector No. and handling of T-
not indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• "Connector No. and pin No." from each branching/merging point:
Shows the ends of branch or source of merging within the parts of the
same wiring harness.
• Arrow (io): Roughly shows the location on the machine.
HM400-2 9
E-1 Engine does not start (Starting motor does not turn) 1
Trouble • Engine does not start (Starting motor does not turn).
Related
• Engine starting circuit is equipped with start lock mechanism of gearshift lever.
information

Trip of circuit breaker (30 A, If circuit breaker is broken, circuit probably has ground fault. (See
1
80 A) cause 11.)
Breakage of fuse (BT2-No.
2 If fuse is broken, circuit probably has ground fault. (See cause 11.)
20, BT3-No. 32)
3 Discharged battery
Battery voltage Electrolyte specific gravity
Min. 24 V Min. 1.26
a Prepare with starting switch OFF, then keep it in OFF position
and start engine and carry out troubleshooting in each case.
Defective starting switch Starting switch Resistance
4
(Internal disconnection)
OFF Min. 1 Mz
Between B – C
START Max. 1 z
Defective engine cut-off relay
5 Replace engine cut-off relay (Right No.) with another
(Internal defect)
relay. If engine starts at this time, engine cut-off relay is R38
defective.
Possible causes out troubleshooting.
Defective engine starting
and standard 6 Replace engine starting relay (Right No.) with another
relay (Internal defect)
value in normal relay. If engine starts at this time, engine starting relay R01
state is defective.
Defective diode D01 (Internal ing without turning starting switch ON.
7
short circuit) D01 (female) Continuity (Resistance)
Between (1) – (2) No continuity (Min. 1 Mz)
Starting motor, 78 Voltage
Between terminal B –
Battery voltage 20 – 30 V
chassis ground
Defective starting motor
8 Between 78 (1) –
(Internal defect) Starting signal 20 – 30 V
chassis ground
Between 78 (2) –
Generation signal Max. 1 V
chassis ground
If battery voltage, starting signal, and generation signal are normal
but starting motor does not turn, starting motor is defective.
Defective alternator (Internal
9 Alternator Voltage
short circuit)
Between R – chassis
Generation signal Max. 1 V
ground
10 HM400-2

Wiring harness between terminal battery (-) Resis-
Max. 1 z
– chassis ground (ER) tance
Wiring harness between battery (+) – junc-
Resis-
tion block - battery relay (66) – circuit Max. 1 z
tance
breaker (82)
Wiring harness between circuit breaker (84) Resis-
Max. 1 z
– BT2 (19) tance
Wiring harness between BT2 (20) – starting Resis-
Max. 1 z
switch (B) tance
Wiring harness between starting switch (C) - Resis-
Max. 1 z
Disconnection in wiring har- Wiring harness between R38 (female) (6) – Resis-
ness (Disconnection in wiring R01 (female) (5) Max. 1 z
10 tance
or defective contact in con-
nector) Wiring harness between R01 (female) (3) – Resis-
Max. 1 z
78 (female) (1) tance
Wiring harness between battery relay (69) – Resis-
Max. 1 z
junction block - circuit breaker (65) tance
Max. 1 z
– BT3 (13) tance
Max. 1 z
(female) (1) tance
Possible causes
Wiring harness between SF1 (female) (5) – Resis-
value in normal
state Wiring harness between R01 (female) (2) – Resis-
Max. 1 z
JCA – chassis ground (ER2) tance
Max. 1 z
starting motor (B) tance
Resis-
tion block – battery relay (66) – circuit Min. 1 Mz
tance
breaker (82)
Min. 1 Mz
– BT2 (19) or circuit branch end tance
Min. 1 Mz
switch (B) tance
Ground fault in wiring har- Wiring harness between starting switch (C) Resis-
Min. 1 Mz
11 ness (Short circuit with GND – R38 (female) (3) or circuit branch end tance
circuit) Wiring harness between R38 (female) (6) – Resis-
Min. 1 Mz
Min. 1 Mz
78 (female) (1) or circuit branch end tance
Min. 1 Mz
junction block – circuit breaker (65) tance
Min. 1 Mz
Min. 1 Mz
(female) (1) or circuit branch end tance
HM400-2 11

Wiring harness between SF1 (female) (5) – Resis-
R01 (female) (1) or circuit branch end tance
circuit)
ossible causes Min. 1 Mz
starting motor (B) tance
and standard
Hot short (Short circuit with Wiring harness between 78 (female) (2) –
12
24V circuit) in wiring harness CJU - alternator (R), D01 (female) (2), ATC1
Voltage Max. 1 V
(female) (15), BRC1 (female) (1), or circuit
branch end
Defective engine controller Engine controller power supply may be defective. Carry out trou-
13
power supply bleshooting for "Failure code CA111".
12 HM400-2
Circuit diagram related to engine starting system
HM400-2 13
E-2 Auto preheater does not operate 1

Trouble • Auto preheater does not operate.
• If engine coolant temperature is below -5°C, auto preheater operates for up to 40 seconds.
Related
• If trouble is detected in auto preheat relay (R07), failure codes [CA2555] and [CA2556] are dis-
information
played.

Trip of circuit breaker (30 A, If circuit breaker is broken, circuit probably has ground fault. (See
1
80 A) cause 9.)
11, BT4-No. 45)
3 Breakage of fuse (300 A) If fuse is broken, circuit probably has ground fault. (See cause 9.)
and turn it ON and carry out troubleshooting in each case.
4
Between terminals B OFF Min. 1 Mz
and ACC ON Max. 1 z
a Prepare with starting switch OFF (with wiring harness con-
nected), then turn starting switch ON and carry out trouble-
shooting.
Defective intake air heater Intake air heater Voltage
5
(Internal disconnection) Between heater terminal – chas-
20 – 30 V
sis ground
If above voltage is normal but heater mounting part is not warmed,
intake air heater is defective.
a Prepare with starting switch OFF (with wiring harness con-
Possible causes nected), then turn starting switch ON and carry out trouble-
and standard shooting.
value in normal Intake air heater relay Voltage/Resistance
state Defective intake air heater Between E11 – chas-
6 Signal 20 – 30 V
relay (Internal defect) sis ground
Between E12 – ter-
Contact Max. 1 z
minal PH0
If signal voltage is normal but contact resistance is abnormal,
intake air heater relay is defective.
Defective auto preheat relay
7 Replace auto preheat relay (Right No.) with another
(Internal defect)
relay. If auto preheater operates at this time, auto pre- R07
heat relay is defective.
Max. 1 z
ness (Disconnection in wiring Resis-
8 tion block – battery relay (66) – circuit Max. 1 z
or defective contact in con- tance
breaker (82)
nector)
Max. 1 z
– BT2 (19) tance
Max. 1 z
switch (B) tance
14 HM400-2

Wiring harness between starting switch Resis-
Max. 1 z
(ACC) – BT2 (1) tance
Wiring harness between BT2 (2) – J2P Resis-
Max. 1 z
(female) (39) tance
Max. 1 z
junction block – circuit breaker (62) tance
Max. 1 z
Disconnection in wiring har- – BT4 (9) tance
ness (Disconnection in wiring Wiring harness between circuit breaker BT4 Resis-
8 Max. 1 z
or defective contact in con- (10) – R07 (female) (5) tance
nector) Resis-
Wiring harness between R07 (3) – E11 Max. 1 z
tance
Max. 1 z
fuse tance
Resis-
Wiring harness between fuse – E12 Max. 1 z
tance
Wiring harness between PH0 – heater ter- Resis-
Max. 1 z
minal tance
value in normal Wiring harness between battery (+) – junc-
state Resis-
tion block – battery relay (66) – circuit Min. 1 Mz
tance
breaker (82)
Min. 1 Mz
Min. 1 Mz
switch (B) tance
Min. 1 Mz
(ACC) – BT2 (1) or circuit branch end tance
Wiring harness between BT2 (2) – J2P Resis-
Min. 1 Mz
Ground fault in wiring har- (female) (39) tance
9 ness (Short circuit with GND Wiring harness between battery relay (69) – Resis-
Min. 1 Mz
circuit) junction block – circuit breaker (62) tance
Min. 1 Mz
Wiring harness between circuit breaker BT4 Resis-
Min. 1 Mz
(10) – R07 (female) (5) tance
Resis-
Wiring harness between R07 (3) – E11 Min. 1 Mz
tance
Min. 1 Mz
fuse tance
Resis-
Wiring harness between fuse – E12 Min. 1 Mz
tance
Wiring harness between PH0 – heater ter- Resis-
Min. 1 Mz
minal tance
HM400-2 15
Circuit diagram related to engine preheater
16 HM400-2
HM400-2 17
E-3 When starting switch is turned ON, machine monitor displays nothing1
Trouble • When starting switch is turned ON, machine monitor displays no lamps and gauges.
Related
information

If circuit breaker is broken, circuit probably has ground fault. (See
cause 5.)
13 and No. 20)
and turn it ON and carry out troubleshooting in each case.
3
Between terminals B OFF Min. 1 Mz
and ACC ON Max. 1 z
Max. 1 z
Resis-
tion block - battery relay (66) – circuit Max. 1 z
tance
breaker (82)
Disconnection in wiring har- Wiring harness between circuit breaker (84) Resis-
ness (Disconnection in wiring – BT2 (19) Max. 1 z
4 tance
nector) Wiring harness between BT2 (20) – starting Resis-
Max. 1 z
Possible causes switch (B) tance
and standard Wiring harness between starting switch Resis-
(ACC) – BT2 (5) tance
state
Wiring harness between BT2 (6) – DPC1 Resis-
Max. 1 z
(female) (6), (7) tance
Wiring harness between DPC1 (female) (9), Resis-
Max. 1 z
(10) – CJL - chassis ground (ER) tance
Resis-
tion block - battery relay (66) – circuit Min. 1 Mz
tance
breaker (82)
Ground fault in wiring har- Wiring harness between circuit breaker (84) Resis-
Min. 1 Mz
5 ness (Short circuit with GND – BT2 (19) tance
circuit) Wiring harness between BT2 (20) – starting Resis-
Min. 1 Mz
switch (B) tance
Min. 1 Mz
(ACC) – BT2 (5) or circuit branch end tance
Min. 1 Mz
DPC1 Voltage
Between (6), (7) – (9), (10) 20 – 30 V
18 HM400-2
Circuit diagram related to machine monitor power supply
HM400-2 19
E-4 When starting switch is turned OFF, machine monitor cannot be

operated 1
• When starting switch is turned OFF and switches are operated, service meter & integrated odome-
Trouble ter, turn signal pilot lamp, and headlamp high beam pilot lamp on machine monitor are not turned
ON or OFF.
Related
information

If circuit breaker is broken, circuit probably has ground fault. (See
cause 4.)
18)
Max. 1 z
Disconnection in wiring har- tion block – battery relay (66) – circuit Resis-
Max. 1 z
ness (Disconnection in wiring breaker (82) tance
3
nector) Wiring harness between circuit breaker (84) Resis-
Max. 1 z
– BT2 (15) tance
Possible causes Wiring harness between BT2 (16) – DPC1 Resis-
value in normal
state Wiring harness between DPC1 (9), (10) – Resis-
Max. 1 z
CJL – chassis ground(ER) tance
Resis-
Ground fault in wiring har- tion block – battery relay (66) – circuit Min. 1 Mz
tance
4 ness (Short circuit with GND breaker (82)
circuit) Wiring harness between circuit breaker (84) Resis-
Min. 1 Mz
Min. 1 Mz
(female) (4), (5) or circuit branch end tance
DPC1 Voltage
Between (4), (5) – (9), (10) 20 – 30 V
20 HM400-2
Circuit diagram related to machine monitor power supply
HM400-2 21
E-5 Alarm buzzer does not stop sounding 1

• When starting switch is turned ON, central warning lamp lights up and alarm buzzer does not stop
Trouble
sounding.
Related • Causes 2 – 7 are alarms for avoiding dangers in operation, which stop when problem in operation is
information solved.

• When failure is detected, central warning lamp lights up and
alarm buzzer sounds (Note: Lamp/Buzzer may not light up/
1 Failure detection sound, depending on each failure)
• In this case, perform troubleshooting for that code (Check fault
history, too)
• When gear shift lever is set in position other than "N" with engine
started and parking brake switch in "Park" position, central warn-
Parking brake dragging
2 ing lamp lights up and alarm buzzer sounds
warning
• If parking brake switch is set in "Travel" position or gear shift
lever is set in "N" position, alarm is turned OFF
• If travel speed exceeds set speed or engine speed increases
abnormally, central warning lamp lights up and alarm buzzer
3 Overrun warning sounds
• If travel speed decreases below set speed or engine speed
decreases to normal range, alarm is turned OFF
• If gear shift lever is set in position other than "N" with parking
brake switch in "Travel" position while engine is running and
dump body is raised (dump body pilot lamp in machine monitor
is lighting), central warning lamp lights up and alarm buzzer
4 Dump body up warning
sounds
• If dump body is lowered or parking brake switch is set in "Park
position" or gear shift lever is set in "N" position, alarm is turned
Possible causes OFF
and standard • If starting switch is turned from OFF to ON, while gear shift lever
value in normal is not in "N" position, central warning lamp lights up and alarm
5 Neutral safety warning
state buzzer sounds
• If gear shift lever is set in "N" position, alarm is turned OFF
• If engine is started and dump body is raised (body pilot lamp in
Warning by dump body up machine monitor is lighting) while this option is set, central warn-
6
caution (if equipped) ing lamp lights up and alarm buzzer sounds
• If dump body is lowered, alarm is turned OFF
• If engine start signal (key switch terminal C) is detected while
gear shift lever is not in "N" position, central warning lamp lights
Warning for start with gear
7 up and alarm buzzer sounds.
shift lever not in neutral
• If gear shift lever is set in "N" position or engine start signal is
turned OFF, alarm is turned OFF
• If accumulator oil pressure is still low after engine is started,
retarder caution lamp (accumulator oil pressure drop detection)
Retarder oil pressure drop of machine monitor and central warning lamp light up and alarm
8
detection buzzer sounds (Reference: Failure code [2G42ZG] or [2G43ZG]
and [DHU2KX] or [DHU3KX] are turned ON after 30 seconds)
• Check retarder hydraulic circuit (accumulator oil pressure)
• If initialization is not performed normally after controller is
replaced, central warning lamp lights up and alarm buzzer
9 Defective initialization
sounds
• Perform initialization correctly
• If any of above causes is not detected, machine monitor or a
Defective machine monitor
10 controller may be defective ((Since trouble is in system, trouble-
or controller
shooting cannot be performed)
22 HM400-2
E-6 Machine monitor does not normally display gauges, caution lamps,
and character display section 1
Trouble (1) Display of gauges is different from machine condition.
Related
information

Possible causes Defective sensor signal sys- Signal system of related sensor may be defective. Check that sen-
1
and standard tem sor.
value in normal When starting switch is turned from OFF position to ON position, if
state 2 Defective machine monitor system does not check gauges normally, machine monitor is
defective.
Trouble (2) Display of caution lamps is different from machine condition.

Related
information

Defective sensor signal sys- Signal system of related sensor or switch may be defective. Check
Possible causes 1
tem that sensor or switch.
and standard
value in normal When starting switch is turned from OFF position to ON position, if
state system does not check lamps normally (lamps must be turned ON
for 2 seconds and then OFF for 1 second), machine monitor is
defective.
Trouble (3) Character display section displays nothing or displays abnormally.

Related
information

Possible causes
and standard When starting switch is turned from OFF position to ON position, if
value in normal system does not check character display section normally
state ("KOMATSU SYSTEM CHECK" must be displayed for 3 seconds
and then OFF for 1 second), machine monitor is defective.
HM400-2 23
E-7 Display of character display section cannot be changed 1

(1) When machine monitor mode selector switch 1 is operated, display of character display section
Trouble
does not change normally.
Related
information

18)
Machine monitor mode
Defective machine monitor CH1 (female) Resistance
selector switch 1
mode selector switch 1
2 [U] is pressed Max. 1 z
(Internal disconnection or
Between (2) – (3)
short circuit) Neutral Min. 1 Mz
Neutral Min. 1 Mz
Between (1) – (3)
[t] is pressed Max. 1 z
Disconnection in wiring har- Wiring harness between BT2 (16) – CH1 Resis-
Max. 1 z
ness (Disconnection in wiring (male) (3) tance
3
nector) Max. 1 z
(8) – CH1 (male) (2) tance
Max. 1 z
Possible causes
and standard
value in normal
state Wiring harness between BT2 (16) – CH1 Resis-
(male) (3) or circuit branch end tance
Min. 1 Mz
Min. 1 Mz
5 Voltage Max. 1 V
24V circuit) in wiring harness (8) – CH1 (male) (2)
Voltage Max. 1 V
(14) – CH1 (male) (1)
DPC2A Voltage
selector switch 1
6 Defective machine monitor [U] is pressed 20 – 30 V
sis ground Neutral Max. 1 V
Between (14) – chas- Neutral Max. 1 V
sis ground [t] is pressed 20 – 30 V
24 HM400-2
(2) When machine monitor mode selector switch 2 is operated, display of character display section
Trouble
does not change normally.
Related
information

30)
Defective machine monitor CH2 (female) Resistance
selector switch 2
mode selector switch 2
2 [>] is pressed Max. 1 z
(Internal disconnection or
Between (2) – (3)
short circuit) Neutral Min. 1 Mz
Neutral Min. 1 Mz
Between (1) – (3)
[<] is pressed Max. 1 z
Disconnection in wiring har- Wiring harness between BT3 (10) – CH2 Resis-
Max. 1 z
3
nector) Max. 1 z
Max. 1 z
Possible causes
and standard
value in normal
state Wiring harness between BT3 (10) – CH2 Resis-
Min. 1 Mz
Min. 1 Mz
5 Voltage Max. 1 V
24V circuit) in wiring harness (6) – CH2 (male) (2)
Voltage Max. 1 V
(15) – CH2 (male) (1)
DPC2A Voltage
selector switch 2
6 Defective machine monitor [>] is pressed 20 – 30 V
etween (6) – chassis
ground Neutral Max. 1 V
sis ground [<] is pressed 20 – 30 V
HM400-2 25
Circuit diagram related to machine monitor mode selector switches 1 and 2
26 HM400-2
HM400-2 27
E-8 Power mode selection function does not operate normally 1

• When power mode selector switch is operated, power mode selection function does not operate
Trouble
normally or power mode pilot lamp is not turned ON or OFF normally.
Related
information

30)
Defective power mode selec- Power mode selec-
2 tor switch (Internal discon- PWM (female) Resistance
tor switch
nection or short circuit)
Upper Min. 1 Mz
Between (1) - (3)
Lower Max. 1 z
ness (Disconnection in wiring Wiring harness between BT3 (10) – PWM Resis-
3 Max. 1 z
or defective contact in con- (male) (1) tance
nector) Wiring harness between DPC2A (female) Resis-
(13) – PWM (male) (3) tance
and standard
Wiring harness between BT3 (10) – PWM Resis-
circuit)
Min. 1 Mz
(13) – PWM (male) (3) tance
5
24V circuit) in wiring harness Wiring harness between DPC2A (female)
Voltage Max. 1 V
(13) – PWM (male) (3)
Power mode selec-
6 Defective machine monitor DPC2A Voltage
tor switch
Between (13) – chas- Upper Max. 1 V
sis ground Lower 20 – 30 V
28 HM400-2
Circuit diagram related to power mode selector switch
HM400-2 29
E-9 AISS function does not operate normally 1

Trouble • When AISS LOW switch is operated, AISS function does not operate normally.
Related
information

30)
Defective AISS LOW switch
2 (Internal disconnection or AISS (female) AISS LOW switch Resistance
short circuit) Upper Min. 1 Mz
Between (1) – (3)
Lower Max. 1 z
ness (Disconnection in wiring Wiring harness between BT3 (10) – AISS Resis-
3 Max. 1 z
(2) – AISS (male) (3) tance
and standard
Wiring harness between BT3 (10) – AISS Resis-
circuit)
Min. 1 Mz
(2) – AISS (male) (3) tance
5
Voltage Max. 1 V
(2) - AISS (male) (3)
6 Defective machine monitor DPC2A AISS LOW switch Voltage
30 HM400-2
Circuit diagram related to AISS LOW switch
HM400-2 31
(Differential lock-up specification) 1
(1) When right and left differential lock-up switch is operated, right and left differential lock-up function
Trouble does not operate normally or right and left differential lock-up pilot lamp is not turned ON or OFF
normally.
Related
information

30)
Defective right and left differ- DEL (female) Resistance
ential lock-up switch
ential lock-up switch (Internal
2 Upper Max. 1 z
disconnection or short cir-
Between (1) – (3)
cuit) Neutral Min. 1 Mz
Neutral Min. 1 Mz
Between (2) – (3)
Lower Max. 1 z
Disconnection in wiring har- Wiring harness between BT3 (10) – DEL Resis-
Max. 1 z
3
nector) Max. 1 z
(2) – DEL (male) (2) tance
Max. 1 z
Possible causes
and standard
value in normal
state Wiring harness between BT3 (10) – DEL Resis-
Min. 1 Mz
Min. 1 Mz
5 Voltage Max. 1 V
24V circuit) in wiring harness (2) – DEL (male) (2)
Voltage Max. 1 V
(3) – DEL (male) (3)
DPC3A Voltage
ential lock-up switch
6 Defective machine monitor Upper 20 – 30 V
sis ground Neutral Max. 1 V
32 HM400-2
Circuit diagram related to right and left differential lock-up switch
HM400-2 33
(2) When right and left differential lock-up pedal is operated, right and left differential lock-up function
Trouble does not operate normally or right and left differential lock-up pilot lamp is not turned ON or OFF
normally.
Related
information

30)
Defective right and left differ-
ential lock-up pedal (Internal Right and left differ-
2 DFS (male) Resistance
disconnection or short cir- ential lock-up pedal
cuit) Released Min. 1 Mz
Between (A) – (B)
Pressed Max. 1 z
ness (Disconnection in wiring Wiring harness between BT3 (10) – DFS Resis-
3 Max. 1 z
or defective contact in con- (male) (A) tance
(1) – DFS (male) (B) tance
and standard
Wiring harness between BT3 (10) – DFS Resis-
(male) (A) or circuit branch end tance
circuit)
Min. 1 Mz
(1) – DFS (male) (B) tance
5
Voltage Max. 1 V
(1) – DFS (female) (B)
ential lock-up pedal
Between (1) – chas- Released Max. 1 V
sis ground Pressed 20 – 30 V
34 HM400-2
Circuit diagram related to right and left differential lock-up switch
HM400-2 35
E-11 Interaxle differential lock-up function does not operate normally 1

• When interaxle differential lock-up switch is operated, function does not operate normally or inter-
Trouble
axle lock-up pilot lamp is not turned ON or OFF normally.
Related
information

30)
Defective interaxle differen- Interaxle differential
2 tial lock switch (Internal dis- DEF (female) Resistance
lock-up switch
connection or short circuit)
Upper Min. 1 Mz
Between (1) – (3)
Lower Max. 1 z
ness (Disconnection in wiring Wiring harness between BT3 (10) – DEF Resis-
3 Max. 1 z
(12) – DEF (male) (3) tance
and standard
Wiring harness between BT3 (10) – DEF Resis-
circuit)
Min. 1 Mz
(12) – DEF (male) (3) tance
5
Voltage Max. 1 V
(12) – DEF (male) (3)
Interaxle differential
lock-up switch
36 HM400-2
Circuit diagram related to interaxle differential lock-up switch
HM400-2 37
E-12 Display of seat belt caution lamp is abnormal 1

Trouble (1) While seat belt is fastened, seat belt caution lamp lights up.
Related
information

30)
Defective seat belt switch SBS (male) Seat belt Resistance
2
Unfastened Min. 1 Mz
Between (1) – (2)
Fastened Max. 1 z
ness (Disconnection in wiring Wiring harness between BT3 (10) – SBS Resis-
3 Max. 1 z
Possible causes or defective contact in con- (female) (1) tance
and standard nector) Wiring harness between DPC2B (female) Resis-
(11) – SBS (female) (2) tance
state
Wiring harness between BT3 (10) – SBS Resis-
circuit)
Wiring harness between DPC2B (female) Resis-
Min. 1 Mz
(11) – SBS (female) (2) tance
DPC2B Seat belt Voltage
Wiring harness Unfastened Max. 1 V
between (11) – chas-
sis ground Fastened 20 – 30 V
38 HM400-2
Trouble (2) While seat belt is not fastened, seat belt caution lamp does not light up.
Related
information

Defective seat belt switch SBS (male) Seat belt Resistance
1
Unfastened Min. 1 Mz
Between (1) – (2)
Fastened Max. 1 z
and standard Hot short (Short circuit with and carry out troubleshooting.
value in normal 2
24V circuit) in wiring harness Wiring harness between DPC2B (female)
state Voltage Max. 1 V
(11) – SBS (female) (2)
PC2B Seat belt Voltage
Wiring harness Unfastened Max. 1 V
between (11) – chas-
sis ground Fastened 20 – 30 V
Circuit diagram related to interaxle differential lock-up switch
HM400-2 39
E-13 Turn signal lamps and pilot lamps do not operate normally 1
Trouble (1) When turn signal lever and hazard lamp switch are operated, no turn signal lamps blink.
Related • Turn signal line is branched at switch and relay toward right, left, front, and rear. If only 1 lamp is
information defective, bulb may be broken or wiring harness on signal side or ground side may be defective.

1 Breakage of fuse (BT1-No. 2) If fuse is broken, circuit probably has ground fault. (See cause 4.)
Defective hazard relay 2
2 Replace hazard relay 2 (Right No.) with another relay.
(Internal defect)
If turn signal lamp blinks at this time, hazard relay 2 is R13
defective.
Disconnection in wiring har- Wiring harness between R13 (female) (3) – Resis-
ness (Disconnection in wiring FLS (female) (3) tance
and standard 3
or defective contact in con- Wiring harness between FLS (female) (4) – Resis-
nector) circuit branch point tance
state
Wiring harness between FLS (female) (1) – Resis-
Max. 1 z
chassis ground (ER2) tance
FLS (female) (3) tance
circuit)
Min. 1 Mz
CM (female) (6) or R12 (female) (1), (3) tance
Defective flasher (Internal If causes 1 – 4 are not detected, flasher may be defective. (Since
5
defect) trouble is in system, troubleshooting cannot be carried out.)
Trouble (2) When turn signal lever and hazard lamp switch are operated, turn signal lamps do blink but light up.
Related
information

and standard 1
24V circuit) in wiring harness Wiring harness between FLS (female) (4) –
value in normal Voltage Max. 1 V
state CM (female) (6) or R12 (female) (1), (3)
Defective flasher (Internal If cause 1 is not detected, flasher may be defective. (Since trouble
2
defect) is in system, troubleshooting cannot be carried out.)
40 HM400-2
(3) When turn signal lever and hazard lamp switch are operated, turn signal lamps on either of both
Trouble
sides do not blink (They blink normally when hazard switch is turned ON, however).
Related • Turn signal line is branched at switch and relay toward right, left, front, and rear. If only 1 lamp is
information defective, bulb may be broken or wiring harness on signal side or ground side may be defective.

CM (male) Turn signal lever Resistance
Defective turn signal lever Neutral Min. 1 Mz
2
(Internal disconnection) Between (6) – (7)
Left Max. 1 z
Neutral Min. 1 Mz
Between (6) – (8)
Right Max. 1 z
Possible causes Defective hazard relay 2
and standard (Internal defect)
value in normal
defective.
state
ness (Disconnection in wiring Wiring harness between BT1 (4) – R13 Resis-
4 Max. 1 z
or defective contact in con- (female) (6) tance
nector) Wiring harness between CM (female) (6) – Resis-
Max. 1 z
circuit branch point tance
Wiring harness between BT1 (4) – R13 Resis-
(female) (6) tance
circuit)
Wiring harness between CM (female) (6) – Resis-
Min. 1 Mz
FLS (female) (4) or R12 (female) (1), (3) tance
HM400-2 41
(4) When hazard lamp switch is turned ON, no turn signal lamps blink (When turn signal lever is oper-
Trouble
ated, however, turn signal lamps blink normally).
Related
information

22)
Defective hazard lamp
2 switch (Internal disconnec- HAZ (male) Hazard lamp switch Resistance
tion) OFF Min. 1 Mz
Between (1) – (3)
ON Max. 1 z
(Internal defect)
defective.
(Internal defect)
Possible causes defective.
state
Wiring harness between BT2 (24) – HAZ Resis-
Max. 1 z
(male) (1) or R13 (male) (5) tance
Disconnection in wiring har- Wiring harness between HAZ (female) (3) – Resis-
Max. 1 z
ness (Disconnection in wiring R12 (female) (5) or R13 (female) (1) tance
5
or defective contact in con- Wiring harness between R12 (female) (6) – Resis-
nector) Max. 1 z
Max. 1 z
Max. 1 z
R12 (female) (1), (3) tance
Wiring harness between BT2 (24) – HAZ Resis-
(male) (1) or R13 (male) (5) tance
circuit) Wiring harness between HAZ (female) (3) – Resis-
Min. 1 Mz
R12 (female) (5) or R13 (female) (1) tance
Min. 1 Mz
R12 (female) (1), (3) or CM (female) (6) tance
42 HM400-2
(5) When hazard lamp switch is turned OFF, turn signal lamps blink (They blink normally when turn
Trouble
signal lever is operated, however).
Related
information

Defective hazard lamp
1 switch (Internal disconnec- HAZ (male) Hazard lamp switch Resistance
tion) OFF Min. 1 Mz
Between (1) – (3)
ON Max. 1 z
Possible causes
value in normal and carry out troubleshooting.
state 2 Replace hazard relay 1 (Right No.) with another relay.
(Internal defect)
defective.
3
24V circuit) in wiring harness Wiring harness between HAZ (female) (3) –
Voltage Max. 1 V
R12 (female) (5) or R13 (female) (1)
Trouble (6) Turn signal pilot lamps do not blink normally (Turn signal lamps blink normally, however).
Related
information

ness (Disconnection in wiring Wiring harness between DPC2A (female) Resis-
1 Max. 1 z
or defective contact in con- (7) – R12 (female) (4) tance
Max. 1 z
(16) – R12 (female) (2) tance
value in normal DPC2A Turn signal lever Voltage
state
Neutral Max. 1 V
Between (7) – chas- Max. 1 V/20 – 30 V
2 Defective machine monitor sis ground Right (Changes between 2
values)
Neutral Max. 1 V
Between (6) – (8) Max. 1 V/20 – 30 V

Left (Changes between 2
values)
HM400-2 43
Circuit diagram related to turn signal lever, turn signal lamps, and turn signal pilot lamps
44 HM400-2
E-14 Night lighting is abnormal 1

(1) When lamp switch is set to 1st or 2nd position, none of small lamps, night lamps, and headlamps
Trouble
light up.
• Lamp and night lighting line is branched at switch and relay toward right, left, front, and rear. If only
Related
1 lamp is defective, bulb may be broken or wiring harness on signal side or ground side may be
information
defective.

CM (male) Lamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch (Inter- Between (1) – (2) 1st position Max. 1 z
2
nal disconnection)
2nd position Max. 1 z
Possible causes
and standard OFF Min. 1 Mz
value in normal Between (1) – (3) 1st position Min. 1 Mz
state
3
or defective contact in con- Wiring harness between BT1 (2) – CM Resis-
nector) Max. 1 z
(female) (1) tance
circuit) Wiring harness between BT1 (2) – CM Resis-
Min. 1 Mz
HM400-2 45
Trouble (2) When lamp switch is set to 1st position, small lamps and night lamps do not light up.
Related
information
defective.

Breakage of fuse (BT1-No. 5
& No. 6)
Defective lamp switch (Inter- CM (male) Lamp switch Resistance

2
nal disconnection) OFF Min. 1 Mz
Between (1) – (2) 1st position Max. 1 z
Possible causes
and standard 2nd position Max. 1 z
ness (Disconnection in wiring Wiring harness between CM (female) (2) – Resis-
3 Max. 1 z
or defective contact in con- BT1 (9), (11) tance
nector) Wiring harness between BT1 (10), (12) – Resis-
Max. 1 z
circuit) Wiring harness between BT1 (10), (12) – Resis-
Min. 1 Mz
circuit branch end tance
Trouble (3) When lamp switch is turned OFF, small lamps and night lamps light up.
Related
information


Possible causes 1
and standard
value in normal Between (1) – (2) 1st position Max. 1 z
state 2nd position Max. 1 z
2
24V circuit) in wiring harness Wiring harness between CM (female) (2) –
Voltage Max. 1 V
circuit branch point
46 HM400-2
Trouble (4) When brightness control switch is operated, brightness of night lighting does not change.
Related
information
defective.

Brightness control
Defective brightness control LS Voltage
switch
1
Between (1) – (3) All range of switch 20 – 30 V
Left end 6 – 10 V
Between (1) – (2)
Right end 18 – 27 V
value in normal
state Disconnection in wiring har- Wiring harness between LS (female) (1) – Resis-
Max. 1 z
ness (Disconnection in wiring circuit branch point tance
2
or defective contact in con- Wiring harness between LS (female) (2) – Resis-
nector) Max. 1 z
Wiring harness between LS (female) (3) – Resis-
Max. 1 z
3
24V circuit) in wiring harness Wiring harness between LS (female) (2) –
Voltage Max. 1 V
circuit branch point
Trouble (5) When lamp switch is set to 2nd position, head lamps do not light up.
Related
information


1
Between (1) – (3) 1st position Min. 1 Mz
Possible causes Defective headlamp relay
2 Replace headlamp relay (Right No.) with another relay.
and standard (Internal defect)
If headlamps light up at this time, headlamp relay is R14
value in normal defective.
state
Max. 1 z
R14 (female) (1) or R15 (female) (1) tance
ness (Disconnection in wiring Wiring harness between R14 (female) (2) – Resis-
3 Max. 1 z
or defective contact in con- JCA – chassis ground (ER2) tance
nector)
Max. 1 z
Max. 1 z
HM400-2 47
Trouble (6) High beam of headlamp does not light up (Low beam lights up, however).
Related
information
defective.

Defective dimmer switch CM (male) Dimmer switch Resistance
2
(Internal disconnection) Max. 1 z/Min. 1 Mz
Between (4) – (5) Raise/Return (Changes between 2
values)
Defective headlamp selector
If low beam lights up at this time, headlamp relay is R15
and standard
Max. 1 z
Disconnection in wiring har- DPC2A (female) (4) tance
4 Max. 1 z
or defective contact in con- DPC2A (female) (14) tance
Max. 1 z
BT1 (5) tance
Wiring harness between BT1 (6) – CJT – Resis-
Max. 1 z
circuit) Wiring harness between BT1 (6) – CJT – Resis-
Min. 1 Mz
48 HM400-2
Trouble (7) Low beam of headlamp does not light up (High beam lights up, however).
Related
information
defective.

Defective dimmer switch CM (male) Dimmer switch Resistance
2
(Internal disconnection) Max. 1 z/Min. 1 Mz
Between (4) – (5) Raise/Return (Changes between 2
values)
Defective headlamp selector
If low beam lights up at this time, headlamp relay is R15
and standard
Max. 1 z
Disconnection in wiring har- DPC2A (female) (4) tance
4 Max. 1 z
or defective contact in con- DPC2A (female) (14) tance
Max. 1 z
BT1 (7) tance
Wiring harness between BT1 (8) – CJT – Resis-
Max. 1 z
circuit) Wiring harness between BT1 (8) – CJT – Resis-
Min. 1 Mz
(8) When high beam of headlamp is turned ON, pilot lamp on machine monitor does not light up (High
Trouble
beam lights up, however).
Related
information

1
or defective contact in con- Wiring harness between DPC2A (1) – circuit Resis-
Possible causes nector) Max. 1 z
branch point tance
and standard
2 Defective machine monitor DPC2A Dimmer switch Voltage
Between (1) – chas- Lo Max. 1 V
sis ground Hi 20 – 30 V
HM400-2 49
Circuit diagram related to night lighting
50 HM400-2
E-15 Backup lamp and backup buzzer operate abnormally 1

Trouble (1) When gearshift lever is set to R1 or R2, backup lamp and backup buzzer do not operate.
Related
information

Defective backup lamp and
2 backup buzzer relay (Internal Replace backup lamp and backup buzzer relay (Right
defect) No.) with another relay. If backup lamp and backup
R5
buzzer operate at this time, backup lamp and backup
buzzer relay is defective.
Possible causes Wiring harness between R05 (female) (5) – Resis-
Max. 1 z
and standard Disconnection in wiring har- circuit branch point tance
value in normal ness (Disconnection in wiring Wiring harness between R05 (female) (6) – Resis-
state 3 Max. 1 z
or defective contact in con- JCA – chassis ground (ER2) tance
nector) Wiring harness between BT1 (16) – R05 Resis-
Max. 1 z
Wiring harness between CJK (female) (6) – Resis-
Max. 1 z
chassis ground (94) tance
circuit)
Wiring harness between BT1 (16) – R05 Resis-
Min. 1 Mz
(2) When gearshift lever is set to R1, backup lamp and backup buzzer do not operate (They operate
Trouble
normally at R2, however).
Related
information

1
disconnection) D06 (male) Continuity
Between (2) – (1) There is continuity
Possible causes
and standard
value in normal ness (Disconnection in wiring Wiring harness between SF1 (female) (4) – Resis-
2 Max. 1 z
state or defective contact in con- D06 (female) (2) tance
nector) Wiring harness between D06 (female) (1) – Resis-
Max. 1 z
circuit) Wiring harness between SF1 (female) (4) – Resis-
Min. 1 Mz
D06 (female) (2) or ATC2 (female) (25) tance
HM400-2 51
(3) When gearshift lever is set to R2, backup lamp and backup buzzer do not operate (They operate
Trouble
normally at R1, however).
Related
information

1
disconnection) D05 (male) Continuity
Between (2) – (1) There is continuity
Possible causes
and standard
value in normal ness (Disconnection in wiring Wiring harness between SF1 (female) (3) – Resis-
2 Max. 1 z
state or defective contact in con- D05 (female) (2) tance
nector) Wiring harness between D05 (female) (1) – Resis-
Max. 1 z
circuit) Wiring harness between SF1 (female) (3) – Resis-
Min. 1 Mz
D05 (female) (2) or ATC2 (female) (35) tance
(4) Right backup lamp and backup buzzer do not operate (Left backup lamp operates normally, how-
Trouble
ever).
• Right backup lamp and backup buzzer use common signal circuit. If only either of them does not
Related
operate, backup lamp bulb may be broken, backup buzzer may be defective, or wiring harness of
information
signal circuit or ground circuit may be defective.

defect) No.) with another relay. If right backup lamp and
Possible causes R5
backup buzzer operate at this time, backup lamp and
and standard backup buzzer relay is defective.
value in normal
2 Max. 1 z
or defective contact in con- circuit branch point tance
Max. 1 z
CJK tance
52 HM400-2
(5) Left backup lamp does not operate (Right backup lamp and backup buzzer operate normally, how-
Trouble
ever).
Related
information

R5
backup buzzer relay is defective.
value in normal
state Disconnection in wiring har- Wiring harness between R05 (female) (2) – Resis-
Max. 1 z
ness (Disconnection in wiring circuit branch point tance
2
or defective contact in con- Wiring harness between R05 (female) (1) – Resis-
nector) Max. 1 z
BL47 (female) (1) tance
Wiring harness between BL47 (female) (2) – Resis-
Max. 1 z
CJZ – CJK – chassis ground (94) tance
If causes 1 – 2 are not detected, left backup lamp may be defec-
3 Defective left backup lamp
tive.
Trouble (6) While gearshift lever is not at R1 or R2, backup lamp and backup buzzer operate.
Related
information

R5
Possible causes backup buzzer relay is defective.
state Wiring harness between R05 (female) (6) –
Voltage Max. 1 V
D05 (female) (1) or D06 (female) (1)
2
24V circuit) in wiring harness Wiring harness between R05 (female) (1) – Voltage Max. 1 V
BL47 (female) (1)
Wiring harness between R05 (female) (3) –
CJK – BL48 (female) (1) or backup buzzer Voltage Max. 1 V
(49)
HM400-2 53
Circuit diagram related to backup lamp and backup buzzer
54 HM400-2
E-16 Emergency steering system does not operate 1

Trouble (1) Emergency steering system does not operate automatically.
• Emergency steering system operates automatically in following cases.
Related
1) Steering hydraulic pump is broken.
information
2) Engine stops while machine is in operation.

33)
Defective parking brake
2 switch (Internal disconnec- B17 (male) Parking brake switch Resistance
tion) Release Max. 1 z
Between (1) – (2)
Apply Min. 1 Mz
Defective emergency steer-
3 ing oil pressure switch (Inter- E02 (male) Steering pump Resistance
nal disconnection) Operated Min. 1 Mz
Between (A) – (C)
Stopped Max. 1 z
Defective emergency steer- EM Voltage

4
ing timer (Internal defect) Between (3) – (1) Switch signal 20 – 30 V
Between (5) – (1) Relay signal (*) 20 – 30 V
* Relay signal is outputted 1 second after switch signal is inputted.
value in normal Emergency steering relay Voltage/Resistance
state Defective emergency steer-
Between coil ends Coil voltage 20 – 30 V
5 ing relay (Internal disconnec-
tion) Between contact ter-
Contact resistance Max. 1 z
minals
* If coil voltage is normal but contact resistance is abnormal, relay
is defective.
Defective emergency steer- Emergency steering motor Voltage
6
ing motor (Internal defect) Between terminals 20 – 30 V
* If above voltage is normal but motor does not operate, motor is
defective.
Wiring harness between BT3 (16) – B17 Resis-
Max. 1 z
Disconnection in wiring har- (female) (1) tance
ness (Disconnection in wiring Wiring harness between B17 (female) (2) – Resis-
7 Max. 1 z
or defective contact in con- E02 (female) (A) tance
nector) Wiring harness between E02 (female) (C) – Resis-
Max. 1 z
EM (female) (3) tance
Wiring harness between EM (female) (1) – Resis-
Max. 1 z
HM400-2 55

Wiring harness between EM (female) (5) – Resis-
Max. 1 z
Disconnection in wiring har- CJL – relay (57), (55), (61), (59) tance
ness (Disconnection in wiring Wiring harness between relay (56), (54), Resis-
7 Max. 1 z
or defective contact in con- (60), (58) – CJL – chassis ground (ER) tance
nector) Wiring harness between relay (73), (77) – Resis-
Max. 1 z
motor (M-2) tance
Wiring harness between motor (E-2) – chas- Resis-
Max. 1 z
Possible causes sis ground tance
state
Wiring harness between BT3 (16) – B17 Resis-
Min. 1 Mz
(female) (1) tance
Wiring harness between B17 (female) (2) – Resis-
Min. 1 Mz
Ground fault in wiring har- CJR – E02 (female) (A) or circuit branch end tance
8 ness (Short circuit with GND Wiring harness between E02 (female) (C) – Resis-
circuit) Min. 1 Mz
EM (female) (3) tance
Wiring harness between EM (female) (5) –
Resis-
CJL – relay (57), (55), (61), (59) or circuit Min. 1 Mz
tance
branch end
Wiring harness between relay (73), (77) – Resis-
Min. 1 Mz
motor (M-2) tance
56 HM400-2
Trouble (2) Emergency steering system cannot be operated manually.

Related
information

23)
Defective emergency steer-
2 ing switch (Internal discon- Emergency steering switch Resistance
nection) Released Min. 1 Mz
Between ST1 – ST2
Pressed Max. 1 z
Emergency steering relay Voltage/Resistance
Between coil termi-
Defective emergency stop Coil voltage 20 – 30 V
3 nals
relay (Internal disconnection)
Between contact ter-
Contact resistance Max. 1 z
minals
* If coil voltage is normal but contact resistance is abnormal, relay
is defective.
Defective emergency steer- Emergency steering motor Voltage
Possible causes 4
and standard ing motor (Internal defect) Between terminals 20 – 30 V
value in normal * If above voltage is normal but motor does not operate, motor is
state defective.
Resis-
Between BT2 (26) – ST1 Max. 1 z
tance
Disconnection in wiring har- Wiring harness between ST2 – CJL – relay Resis-
Max. 1 z
ness (Disconnection in wiring (57), (55), (61), (59) tance
5
or defective contact in con- Wiring harness between relay (56), (54), Resis-
nector) Max. 1 z
(60), (58) – CJL – chassis ground (ER) tance
Max. 1 z
motor (M-2) tance
Wiring harness between motor (E-2) – chas- Resis-
Max. 1 z
sis ground tance
Resis-
Ground fault in wiring har- Wiring harness between BT2 (2) – ST1 Min. 1 Mz
tance
circuit) Wiring harness between ST2 – CJL – relay Resis-
Min. 1 Mz
(57), (55), (61), (59) or circuit branch end tance
Min. 1 Mz
motor (M-2) tance
HM400-2 57
Circuit diagram related to emergency steering system
58 HM400-2
HM400-2 59

© 2009 KOMATSU
All Rights Reserved
60 HM400-2
SEN01117-00
HM400-2

HM400-2 2001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Information in troubleshooting table...................................................................................................... 3
H-1 Machine does not start.................................................................................................................. 4
H-2 Travel is not smooth (Machine hunts) ........................................................................................... 6
H-3 Lockup is not reset........................................................................................................................ 6
H-4 Start shock and gear shift shock are abnormally large ................................................................. 7
H-5 Gear is not shifted up .................................................................................................................... 8
H-6 Travel speed or power is low ...................................................................................................... 10
H-7 Start and gearshift time lag is large ............................................................................................ 14
H-8 Torque converter oil temperature is high .................................................................................... 16
H-9 Torque converter oil temperature is low...................................................................................... 17
H-10 Front brake does not work fully ................................................................................................. 18
H-11 Center brake does not work fully .............................................................................................. 19
H-12 Rear brake does not work fully ................................................................................................. 20
HM400-2 1
H-13 Steering wheel is heavy ............................................................................................................ 21

H-14 Steering wheel does not move.................................................................................................. 22
H-15 Steering wheel waggle .............................................................................................................. 23
H-16 Dump body raising speed is low ............................................................................................... 24
H-17 Dump body does not move ....................................................................................................... 25
H-18 Hydraulic drift of dump body is large......................................................................................... 26
2 HM400-2
Troubleshooting of hydraulic and mechanical system (H-mode)1

a The following information is summarized in the troubleshooting table. Before carrying out troubleshoot-
ing, understand that information fully.
Trouble Trouble which occurred in the machine

Related
information
Possible causes 2
state ence numbers, which do
not indicate priority)
3
HM400-2 3
H-1 Machine does not start 1

Trouble • Machine does not start.
• Check that transmission oil level is normal.
• If any failure code of input shaft speed sensor system or mechanical system is displayed or
Related
recorded, carry out troubleshooting for it first.
information
• Check that drive shaft etc. are free from trouble.
• Check that parking brake is released securely.

Clogged power train pump
1 Power train pump strainer may be clogged. Check it directly.
strainer
Air in suction side of power Air may be sucked in power train pump suction piping. Check it
2
train pump directly.
Gearshift lever Engine speed Relief pressure
Low set pressure of power
3 2.36 ± 0.20 MPa
train main relief valve Low idle
{24.1 ± 2.0 kg/cm2}
N
2.64 ± 0.20 MPa
High idle
{26.9 ± 2.0 kg/cm2}
a Prepare with starting switch OFF, then run engine at high idle
Improper torque converter oil
0.91 ± 0.10 MPa
4 pressure (Defective relief Torque converter inlet pressure
{9.3 ± 1.0 kg/cm2}
valve)
0.59 ± 0.10 MPa
Torque converter outlet pressure
Possible causes {6.0 ± 1.0 kg/cm2}
and standard a Prepare with starting switch OFF, then run engine at high idle
state 5 Defective torque converter
Power mode Torque converter stall speed
High power 1,832 ± 100
a Prepare with starting switch OFF, then run engine at low idle
Gear speed
Gear speed clutch Clutch pressure
(See table)
2.55 ± 0.15 MPa
Lo F1
Defective gear speed clutch {26.0 ± 1.5 kg/cm2}
6
ECMV 2.55 ± 0.15 MPa
Hi F2
{26.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
1st F1
{26.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
R R1
{26.0 ± 1.5 kg/cm2}
If oil pressure checked in cause 6 is low, seal ring or ring groove of
gear speed clutch piston may be worn. Check them directly.
7 Defective gear speed clutch
If oil pressure checked in cause 6 is normal, gear speed clutch
may be slipping. Check it directly.
4 HM400-2

If oil pressure check in cause 3 is abnormal, power train pump may
Possible causes be defective. Check it by following method.
and standard 1) Disconnect power train pump outlet hose.
8 Defective power train pump
value in normal 2) Rotate engine by engine front section with hand.
state 3) If oil flows out of pump, pump is normal.
* Check line filter for foreign matter, too.
9 Defect in transmission Transmission may have defect in it. Check it directly.
Table: Combinations of gear speed and clutch used
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM400-2 5
H-2 Travel is not smooth (Machine hunts) 1

Trouble • Travel is not smooth (Machine hunts).
Related
• If any failure code of mechanical system is displayed or recorded, carry out troubleshooting for it
information
first.

strainer
2
and standard Gearshift lever Engine speed Relief pressure
value in normal Low set pressure of power
3 2.36 ± 0.20 MPa
state train main relief valve Low idle
{24.1 ± 2.0 kg/cm2}
N
2.64 ± 0.20 MPa
High idle
{26.9 ± 2.0 kg/cm2}
H-3 Lockup is not reset 1

Trouble • Torque converter lockup is not reset.
Related
information
first.

Lockup clutch pres-
Possible causes Gear speed Lockup pilot lamp
Defective lockup solenoid sure
and standard 1
valve 0 MPa
value in normal OFF
state {0 kg/cm2}
Travel at F1
1.81 ± 0.20 MPa
ON
{18.5 ± 2.0 kg/cm2}
If oil pressure checked in cause 1 is normal, lockup clutch may be
2 Defective lockup clutch
seized. Check it directly.
6 HM400-2
H-4 Start shock and gear shift shock are abnormally large 1
Trouble • Start shock and gear shift shock are abnormally large
Related • If any failure code of mechanical system is displayed or recorded, carry out troubleshooting for it
information first.

Possible causes Judge that shocks are abnormally large in following cases.
and standard • Shocks are clearly larger than before.
value in normal Defective gear speed clutch • Shocks are larger than those of another machine of same
1
state ECMV model.
Gear speed clutch ECMV may be malfunctioning. Check it directly.
HM400-2 7
H-5 Gear is not shifted up 1

Trouble • Gear is not shifted up.
information first.

1 2.36 ± 0.20 MPa
{24.1 ± 2.0 kg/cm2}
N
2.64 ± 0.20 MPa
High idle
{26.9 ± 2.0 kg/cm2}
Defective lockup solenoid Lockup clutch pres-
2 Gear speed Lockup pilot lamp
valve sure
1.81 ± 0.20 MPa
Travel at F1 ON
{18.5 ± 2.0 kg/cm2}
If gear is shifted up, lockup clutch may be slipping. Check it
directly.
Possible causes a Prepare with starting switch OFF, then run engine at low idle
value in normal Gear speed
state Gear speed clutch Clutch pressure
(See table)
2.55 ± 0.15 MPa
Lo F1
{26.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
Hi F2
4
ECMV 2.55 ± 0.15 MPa
1st F1
{26.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
2nd F3
{26.0 ± 1.5 kg/cm2}
2.45 ± 0.15 MPa
3rd F5
{25.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
R R1
{26.0 ± 1.5 kg/cm2}
8 HM400-2
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM400-2 9
H-6 Travel speed or power is low 1

Trouble (1) Travel speed or power is low at all gear speeds (during lockup travel).
Related
first.
information
• Check that parking brake is released securely and retarder is not dragging.
• Check that tire inflation pressure is normal.

strainer
2
3 2.36 ± 0.20 MPa
{24.1 ± 2.0 kg/cm2}
N
2.64 ± 0.20 MPa
High idle
{26.9 ± 2.0 kg/cm2}
and standard Defective lockup solenoid Lockup clutch pres-
4 Gear speed Lockup pilot lamp
value in normal valve sure
state 1.81 ± 0.20 MPa
Travel at F1 ON
{18.5 ± 2.0 kg/cm2}
lockup clutch piston may be worn. Check them directly.
If oil pressure checked in cause 4 is normal, lockup clutch may be
slipping. Check it directly.
If check result of cause 3 is abnormal, power train pump may be
defective. Check line filter directly for aluminum powder etc.
If causes 1 – 6 are not detected, check torque converter stall
speed. If it is low, engine performance may have lowered.
7 Low engine performance and carry out troubleshooting.
10 HM400-2
Trouble (2) Travel speed or power is low at during torque converter travel.
Related
first.
information
• Check that oil is not leaking from power train piping.
• Check that parking brake is released securely and retarder is not dragging.

1 2.36 ± 0.20 MPa
{24.1 ± 2.0 kg/cm2}
N
2.64 ± 0.20 MPa
High idle
and standard a Prepare with starting switch OFF, then run engine at high idle
state Improper torque converter oil
0.91 ± 0.10 MPa
2 pressure (Defective relief Torque converter inlet pressure
{9.3 ± 1.0 kg/cm2}
valve)
0.59 ± 0.10 MPa
{6.0 ± 1.0 kg/cm2}
3 Defective torque converter
HM400-2 11
Trouble (3) Travel speed or power is low at specific gear speed.

Related
information
first.

Gear speed
(See table)
2.55 ± 0.15 MPa
Lo F1
{26.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
Hi F2
Possible causes 1
ECMV 2.55 ± 0.15 MPa
and standard 1st F1
{26.0 ± 1.5 kg/cm2}
value in normal
state 2.55 ± 0.15 MPa
2nd F3
{26.0 ± 1.5 kg/cm2}
2.45 ± 0.15 MPa
3rd F5
{25.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
R R1
{26.0 ± 1.5 kg/cm2}
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
12 HM400-2
H-7 Start and gearshift time lag is large 1

Trouble • Start and gearshift time lag is large.
information first.

strainer
2
3 2.36 ± 0.20 MPa
{24.1 ± 2.0 kg/cm2}
N
2.64 ± 0.20 MPa
High idle
{26.9 ± 2.0 kg/cm2}
Gear speed
Possible causes (See table)
and standard 2.55 ± 0.15 MPa
value in normal Lo F1
{26.0 ± 1.5 kg/cm2}
state
2.55 ± 0.15 MPa
Hi F2
4
ECMV 2.55 ± 0.15 MPa
1st F1
{26.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
2nd F3
{26.0 ± 1.5 kg/cm2}
2.45 ± 0.15 MPa
3rd F5
{25.0 ± 1.5 kg/cm2}
2.55 ± 0.15 MPa
R R1
{26.0 ± 1.5 kg/cm2}
14 HM400-2
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM400-2 15
H-8 Torque converter oil temperature is high 1

Trouble • Torque converter oil temperature is high.
Related
first.
information
• If oil temperature rises when torque converter is stalled and lowers when gear is returned to neutral,
machine is normal and overloaded.

strainer
2
3 Power train pump line filter may be clogged. Check it directly.
line filter
4 2.36 ± 0.20 MPa
N
and standard 2.64 ± 0.20 MPa
value in normal High idle
{26.9 ± 2.0 kg/cm2}
state
Defective torque converter and carry out troubleshooting.
6
relief valve 0.91 ± 0.10 MPa
Torque converter inlet pressure
{9.3 ± 1.0 kg/cm2}
0.91 ± 0.10 MPa
7 Defective torque converter Torque converter inlet pressure
{9.3 ± 1.0 kg/cm2}
0.59 ± 0.10 MPa
{6.0 ± 1.0 kg/cm2}
16 HM400-2
H-9 Torque converter oil temperature is low 1

Trouble • Torque converter oil temperature is low.
information first.

strainer
2
3 2.36 ± 0.20 MPa
{24.1 ± 2.0 kg/cm2}
N
Possible causes 2.64 ± 0.20 MPa
High idle
and standard {26.9 ± 2.0 kg/cm2}
value in normal If check result of cause 3 is abnormal, power train pump may be
state 4 Defective power train pump
Defective torque converter and carry out troubleshooting.
5
relief valve 0.91 ± 0.10 MPa
Torque converter inlet pressure
{9.3 ± 1.0 kg/cm2}
0.91 ± 0.10 MPa
6 Defective torque converter Torque converter inlet pressure
{9.3 ± 1.0 kg/cm2}
0.59 ± 0.10 MPa
{6.0 ± 1.0 kg/cm2}
HM400-2 17
H-10 Front brake does not work fully 1

Trouble • Front brake does not work fully.
information first.

Air in suction side of brake Air may be sucked in brake control pump suction piping. Check it
1
control pump directly.
Defective accumulator 11.77 (+0.49/0) MPa
2 Charge cut-in pressure
charge valve {120 (+5.0/0) kg/cm2}
20.59 ± 0.98 MPa
Charge cut-out pressure
{210 ± 10 kg/cm2}
If brake begins not to work just after engine is stopped, accumula-
Defective front brake accu- tor may not be fully charged with gas.
3
mulator Charge gas pressure 4.4 ± 0.15 MPa
(Reference) {45 ± 1.5 kg/cm2}
Possible causes a Prepare with starting switch OFF, then run engine at high idle
value in normal 4 Defective front brake valve Brake pedal Brake operating pressure
state
4.9 ± 0.49 MPa
Pressed fully
{50 ± 5.0 kg/cm2}
Defective front brake and carry out troubleshooting.
5 retarder pressure reducing Retarder control lever Brake operating pressure
valve 4.9 ± 0.49 MPa
Max. braking position
{50 ± 5.0 kg/cm2}
If there is time lag at start of braking or if abnormally pressing force
Defective front brake slack
6 is required to obtain specified braking force, slack adjuster may be
adjuster
defective. Check it directly.
If oil pressure checked in causes 4 and 5 is low, seal ring or ring
groove of brake piston may be worn. Check them directly.
7 Defective front wheel brake
If oil pressure checked in causes 4 and 5 is normal, brake disc may
be slipping. Check it directly.
18 HM400-2
H-11 Center brake does not work fully 1

Trouble • Center brake does not work fully.
information first.

1
and carry out troubleshooting
20.59 ± 0.98 MPa
{210 ± 10 kg/cm2}
Defective rear brake accu- tor may not be fully charged with gas.
3
Possible causes a Prepare with starting switch OFF, then run engine at high idle
value in normal 4 Defective rear brake valve Brake pedal Brake operating pressure
state
4.9 ± 0.49 MPa
Pressed fully
{50 ± 5.0 kg/cm2}
Defective rear brake retarder
5 Retarder control lever Brake operating pressure
pressure reducing valve
4.9 ± 0.49 MPa
Max. braking position
{50 ± 5.0 kg/cm2}
Defective center brake slack
adjuster
7 Defective center wheel brake
HM400-2 19
H-12 Rear brake does not work fully 1

Trouble • Rear brake does not work fully.
information first.

1
20.59 ± 0.98 MPa
{210 ± 10 kg/cm2}
Defective rear brake accu- tor may not be fully charged with gas.
Possible causes 3
and standard
value in normal
state a Prepare with starting switch OFF, then run engine at high idle
4 Defective rear brake valve Brake pedal Brake operating pressure
4.9 ± 0.49 MPa
Pressed fully
{50 ± 5.0 kg/cm2}
Defective rear brake slack
adjuster
6 Defective rear wheel brake
20 HM400-2
H-13 Steering wheel is heavy 1

Trouble • Steering wheel is heavy.
• Check that hydraulic tank oil level is normal.
first.
Related
• Check that steering wheel has normal play (While engine is stopped: Max. 150 mm).
information
• Before starting troubleshooting, check that hinge pin etc. are fully greased.
• Before starting troubleshooting, adjust tire inflation pressure properly (29.5-R25: 0.372 MPa {3.8 kg/
cm2}.

Air in suction side of steering Air may be sucked in steering and work equipment pump suction
1
and work equipment pump piping. Check it directly.
Clogged steering and work Steering and work equipment pump strainer may be clogged.
2
equipment pump strainer Check it directly.
Defective relief valve of flow-
3 Steering cylinder Steering relief pressure
amplifier valve
20.59 (+0.98/0) MPa
Stroke end
{210 (+10/0) kg/cm2}
4 Defective steering valve Steering cylinder Steering relief pressure
Possible causes 20.59 (+0.98/0) MPa

Stroke end
and standard {210 (+10/0) kg/cm2}
value in normal Malfunction of flow-amplifier If oil pressure is normal, flow-amplifier valve spool may be malfunc-
5
state valve spool tioning. Check it directly.
Steering cylinder Steering relief pressure
20.59 (+0.98/0) MPa
Stroke end
{210 (+10/0) kg/cm2}
6 Defective steering cylinder a Prepare with starting switch OFF, then run engine at low idle
If oil pressure is low, disconnect hydraulic hose on steering cylin-
der head side and relieve steering cylinder at extension stroke end.
If oil flows out of cylinder at this time, piston ring of cylinder is
defective.
If check result of causes 3 and 4 is abnormal, steering and work
Defective steering and work
7 equipment pump may be defective. Check line filter directly for
equipment pump
aluminum powder etc.
HM400-2 21
H-14 Steering wheel does not move 1

Trouble • Steering wheel does not move.
Related
first.
information
• Check that steering wheel has normal play (While engine is stopped: Max. 150 mm).
• Before starting troubleshooting, check that hinge pin etc. are fully greased.

If dump body does not move either, PTO may be defective. Check
1 Defective PTO
it directly.
2
3
amplifier valve
20.59 (+0.98/0) MPa
Stroke end
{210 (+10/0) kg/cm2}
5 Defective steering valve Steering cylinder Steering relief pressure
Possible causes
and standard 20.59 (+0.98/0) MPa
Stroke end
value in normal {210 (+10/0) kg/cm2}
state Malfunction of flow-amplifier If oil pressure is normal, flow-amplifier valve spool may be malfunc-
6
valve spool tioning. Check it directly.
20.59 (+0.98/0) MPa
Stroke end
{210 (+10/0) kg/cm2}
7 Defective steering cylinder a Prepare with starting switch OFF, then run engine at low idle
defective.
If check result of causes 4 and 5 is abnormal, steering and work
Defective steering and work
8 equipment pump may be defective. Check line filter directly for
equipment pump
aluminum powder etc.
22 HM400-2
H-15 Steering wheel waggle 1

Trouble • Steering wheel waggle.
Related
information
first.

1 Deteriorated oil Oil may be deteriorated. Check it directly.
Possible causes
and standard 20.59 (+0.98/0) MPa
Stroke end
value in normal {210 (+10/0) kg/cm2}
state 2 Defective steering cylinder a Prepare with starting switch OFF, then run engine at low idle
defective.
HM400-2 23
H-16 Dump body raising speed is low 1

Trouble • Dump body raising speed is low
information first.
• Check that dump lever moves smoothly.

1
2
amplifier valve
20.59 (+0.98/0) MPa
Stroke end
{210 (+10/0) kg/cm2}
Defective relief valve of and carry out troubleshooting.
4 dump EPC valve (Pilot pres- Dump lever Dump pilot relief pressure
sure) 3.4 ± 0.49 MPa
Raise position
{35 ± 5 kg/cm2}
If oil pressure checked in cause 4 is low, dump EPC valve may be
5 Defective dump EPC valve
Possible causes malfunctioning. Check it directly.
and standard Defective dump EPC valve If oil pressure checked in cause 4 is low, pilot pump in dump EPC
value in normal 6
pilot pump valve circuit may be defective. Check it directly.
state
Defective relief valve of
7 Dump cylinder Dump relief pressure
dump valve
20.59 (+0.98/0) MPa
Raise stroke end
{210 (+10/0) kg/cm2}
Malfunction of dump valve If oil pressure checked in cause 7 is abnormal, dump valve spool
8
spool may be malfunctioning. Check it directly.
Dump cylinder Dump relief pressure
20.59 (+0.98/0) MPa
Raise stroke end
{210 (+10/0) kg/cm2}
9 Defective dump cylinder
a Prepare with starting switch OFF (Be sure to use body pivot
pin), then run engine at low idle and carry out troubleshooting.
If oil pressure is low, disconnect hydraulic hose on dump cylinder
head side and relieve dump cylinder at raise stroke end. If oil flows
out of cylinder at this time, piston ring of cylinder is defective.
24 HM400-2
H-17 Dump body does not move 1

Trouble • Dump body does not move
information first.
• Check that dump lever moves smoothly.

If steering wheel does not move either, PTO may be defective.
1 Defective PTO
Check it directly.
2
3
amplifier valve
20.59 (+0.98/0) MPa
Stroke end
{210 (+10/0) kg/cm2}
Defective relief valve of and carry out troubleshooting.
5 dump EPC valve (Pilot pres- Dump lever Dump pilot relief pressure
sure) 3.4 ± 0.49 MPa
Raise position
{35 ± 5 kg/cm2}
Possible causes If oil pressure checked in cause 5 is low, dump EPC valve may be
6 Defective dump EPC valve
and standard malfunctioning. Check it directly.
value in normal Defective dump EPC valve If oil pressure checked in cause 5 is low, pilot pump in dump EPC
state 7
pilot pump valve circuit may be defective. Check it directly.
Defective relief valve of
8 Dump cylinder Dump relief pressure
dump valve
20.59 (+0.98/0) MPa
Raise stroke end
{210 (+10/0) kg/cm2}
Malfunction of dump valve If oil pressure checked in cause 8 is abnormal, dump valve spool
9
spool may be malfunctioning. Check it directly.
Dump cylinder Dump relief pressure
20.59 (+0.98/0) MPa
Raise stroke end
{210 (+10/0) kg/cm2}
10 Defective dump cylinder
If oil pressure is low, disconnect hydraulic hose on dump cylinder
out of cylinder at this time, piston ring of cylinder is defective.
HM400-2 25
H-18 Hydraulic drift of dump body is large 1

Trouble • Hydraulic drift of dump body is large
information first.

Low oiltightness (Defective Raise dump body and disconnect hydraulic hose on dump cylinder
1
seal) of dump valve spool head side and relieve dump cylinder at raise stroke end. If oil does
Possible causes
not flow out of dump cylinder at this time, oiltightness of dump
and standard
valve spool is low (seal is defective).
value in normal
state a Prepare with starting switch OFF (Be sure to use body pivot
2 Defective dump cylinder Raise dump body and disconnect hydraulic hose on dump cylinder
out of dump cylinder at this time, piston ring of dump cylinder is
defective.
26 HM400-2

© 2006 KOMATSU
All Rights Reserved
28 HM400-2
SEN01118-01
HM400-2

HM400-2 2001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 4
S-1 Starting performance of engine is poor .................................................................................................... 8
S-2 Engine does not start ............................................................................................................................. 10
S-3 Engine does not pick up smoothly.......................................................................................................... 14
S-4 Engine stops during operation................................................................................................................ 15
S-5 Engine does not rotate smoothly ............................................................................................................ 16
S-6 Engine lack output (or lacks power) ....................................................................................................... 17
S-7 Exhaust gas is black (incomplete combustion) ...................................................................................... 18
S-8 Oil consumption is excessive (or exhaust gas is blue) ........................................................................... 20
S-9 Oil becomes dirty quickly........................................................................................................................ 21
S-10 Fuel consumption is excessive............................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 23
S-12 Oil pressure drops ................................................................................................................................ 24
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 26
S-14 Coolant temperature becomes too high (Overheating) ........................................................................ 28
HM400-2 1
S-15 Abnormal noise is made ....................................................................................................................... 29

S-16 Vibration is excessive ........................................................................................................................... 30
2 HM400-2
HM400-2 3
Method of using troubleshooting chart 1

The troubleshooting chart consists of the "questions", "check items", "causes", and "troubleshooting" blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
[Questions]
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right. The
items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
[Check items]
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on
the right.
[Causes]
Items to be narrowed from the questions and check items. The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]
Items used to find out the true cause by verifying the narrowed causes finally in order from the most
probable one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 HM400-2
HM400-2 5
<Example of troubleshooting> Exhaust gas is black(Incomplete combustion)

Let us assume that a trouble of "Exhaust gas is black" occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; "Exhaust gas slowly became
black", "Power slowly became weaker", and "Dust indicator is lighting red".
6 HM400-2
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting]
is explained according to Step 1 - Step 3 shown below.
HM400-2 7
S-1 Starting performance of engine is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)
Leaking or clogged fuel piping or entry of air

q Insufficient supply of fuel
Clogged air breather hole of fuel tank cap

Insufficient intake of air
Defective contact of valve and vale seat

q
Defective alternator (generator section)

Defective alternator (regulator section)
Stuck or seized supply pump plunger
q Improper selection of fuel
Defective intake air heater system

Coolant in exhaust pipe
Defective or deteriorated battery

q
Clogged feed pump gauze filter

a The common rail fuel injection system (CRI) recog-
Clogged air cleaner element
Clogged fuel filter element

nizes the fuel injection timing electrically. Accord-
Worn piston ring, cylinder

ingly, even if the starting operation is carried out, the
engine may not start until the crankshaft revolves 2
Defective injector
turns at maximum. This phenomenon does not indi-
cate a trouble, however
Confirm recent repair history

Degree of use of
machine
Operated for long period E E E E E
Became worse gradually Q Q w w Q Q

Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is used Q Q Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w Q Q
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w
During operation, charge level monitor indicates abnormal charge
(if monitor is installed) w w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
Priming pump is too light or too heavy to operate w Q Q
Starting motor cranks engine slowly Q w
While engine is When air bleeding plug of fuel filter is removed, fuel does not
flow out w w
rotated with starting
motor When spill hose from injector is disconnected, little fuel spills w
Check items
Immediately after engine is started, temperature of exhaust manifold of a cylinder is

low w
Engine does not pick up smoothly and combustion is irregular Q Q w

Engine hunts (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows
out (*1) q
Compression pressure is low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter and strainer directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*2)" indicated by
code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
When starting switch is turned to HEAT, intake air heater mount does not become
warm q
Is voltage of 20 – 30 V generated between alternator terminals B and E Yes q

while engine is running at low idle? No q
Specific gravity of electrolyte and battery voltage are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 HM400-2
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and see if the coolant flows out.
A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent,
however, it is not a problem.
*2: Displayed failure codes: [CA559] and [CA2249]
HM400-2 9
S-2 Engine does not start 1

a) Engine does not rotate Causes
General causes why engine does not rotate
Cracked EGR cooler (Coolant in exhaust pipe)
Defective starting motor (safety relay section)

q Seized internal parts of engine
o See "S-4 Engine stops during operation"
Defective connection of battery terminal
Defective starting motor (motor section)

q Water hammer caused by coolant which entered cylinder
q Defective electrical system
Defective starting circuit wiring

q Trouble in drive devices on applicable machine side
o Carry out troubleshooting for devices on applicable machine
Broken flywheel ring gear
Defective starting switch

Defective battery relay
Questions
Degree of use of
Operated for long period E E E
machine
When starting switch is Horn does not sound Q Q w
turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
When starting switch is turned ON, no operating sound comes out from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn w Q Q w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Carry out troubleshooting on

Inspect flywheel ring gear directly q
applicable machine side

Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminals B

q
and E
Turn starting switch When terminals B and C of starting switch are connected, engine
OFF, connect cables, q
starts
turn starting switch ON,
and carry out trouble- When terminals B and C at safety relay outlet are connected, engine q
shooting starts
Even if terminals B and C at safety relay outlet are connected,
q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
10 HM400-2

HM400-2 11
b) Engine rotates but no exhaust gas comes out Causes

General causes why engine rotates but no exhaust gas
Malfunction of overflow valve (Does not close)

comes out

Fuel is not supplied
Wrong connection of supply pump PCV

q
Seized or abnormally worn feed pump

q Supply of fuel is extremely small
Broken supply pump shaft or key

q Improper selection of fuel (particularly in winter)
Defective supply pump PCV

Clogged fuel filter element
Malfunction flow damper

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Degree of use of
Operated for long period E E E
machine
Exhaust gas suddenly stopped coming out (when starting again) w Q w w w E E
Filters have not been replaced according to Operation and Maintenance Manual w w E Q
Fuel tank is empty w
Air breather hole of fuel tank cap is clogged Q w
There are rust and water in fuel drained from fuel tank Q Q Q Q Q
There is not fuel in removed fuel filter w w
Fuel is leaking from fuel piping w
Check items

When air bleeding plug of fuel filter is removed, fuel does Q Q w Q
While engine is not flow out
rotated with starting
motor When spill hose from injector is disconnected, little fuel
spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indi- q q q q
cated by code
Carry out troubleshooting according to "PCV1 Short/Open Error (*2) or PCV2
Short/Open Error (*3)" indicated by code q
Inspect overflow valve directly q

Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
*1: Displayed failure codes [CA559] and [CA2249]

12 HM400-2
c) Exhaust gas comes but engine does not start Causes
Defective coolant temperature sensor or wiring harness

(fuel is injected)
Worn dynamic valve system (Valve, rocker lever, etc.)

General causes why exhaust gas comes out but engine does
not startt
Leaking or clogged fuel system or entry of air

q Lack of rotating force due to defective electrical system


q Insufficient intake of air
Clogged injector or defective spray
Defective intake air heater system

Worn piston ring or cylinder liner

Clogged fuel filter or strainer
Use of improper fuel

Degree of use of machine Operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is used Q Q

Filters have not been replaced according to Operation and Maintenance Manual w w w
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indi-
cate normally (if monitor is installed) w
Dust indicator is red (if it is installed) w

Air breather hole of fuel tank cap is clogged Q
There are rust and water in fuel drained from fuel tank w w
There is not fuel in removed fuel filter w
Starting motor rotates engine slowly w
When engine is rotated, abnormal sound comes out from around cylinder head w
Check items
When air bleeding plug of fuel filter is removed, fuel does not
While engine is rotated flow out Q w w
with starting motor,
When spill hose from injector is disconnected, little fuel spills w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w

Inspect dynamic valve system directly q
Compression pressure is low q
Troubleshooting

code q
When injector unit is tested, spray condition is bad q

Coolant temperature gauge does not indicate normally (if it is installed) q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
HM400-2 13
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Malfunction of flow damper (Large leakage from injector)

q
Seized turbocharger or interference of turbocharger

q Defective condition of fuel spray

q Control by controller in derate mode

Defective contact of valve and valve seat
(limiting injection rate (output) because of an error in

electrical system)
Clogged injector or defective spray

EGR valve stuck open

q

(There is much EGR gas and intake of air is insufficient)
Improper valve clearance

Stuck EGR valve
Degree of use of
machine
Operated for long period E E E E E E
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is used w w w w
Filters have not been replaced according to Operation and Maintenance Manual w w w
Oil must be added more frequently w
Dust indicator is red (if indicator is installed) w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low Q w
Blue under light load w
Exhaust gas color
Black w Q w w
Check items
When engine is rotated, interference sound comes out from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
Engine hunts (rotation is irregular) Q Q w Q

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code q
Inspect valve clearance directly q
Troubleshooting
Turbocharger is heavy to rotate with hand q

code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

14 HM400-2
S-4 Engine stops during operation 1

General causes why engine stops during operation Causes
Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)
Trouble in drive devices on applicable machine side

q Overheating
q Trouble in drive devices on applicable machine
Broken or seized piston or connecting rod

side
o Carry out troubleshooting for devices on appli-

Broken or seized crankshaft bearing
cable machine
Broken supply pump shaft or key

Leaking or clogged fuel piping
Broken or seized feed pump

Broken or seized gear train
Degree of use of
machine Operated for long period E E
Made abnormal noise stopped suddenly w w w w Q w Q w w

w Q Q
Questions
Overheated and stopped

Engine
Stopped slowly w Q Q
Hunted and stopped w Q Q Q Q
Non-specified fuel is used Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w w
Fuel level monitor indicates low level (if monitor is installed) w

There are metal particles in oil drained from oil pan w w Q Q
Check items
Engine does not rotate at all w w

When engine is Engine rotates in opposite direction w
rotated with hand Engine moves by gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when load is applied to machine w

Carry out troubleshooting
Inspect piston and connecting rod directly q

on applicable machine
Inspect crankshaft bearing directly q

Troubleshooting
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" q q
indicated by code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is
removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
HM400-2 15
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Air in fuel system
Malfunction of flow damper (Large leakage from injector)

q
q Defective speed sensor
Clogged injector or defective spray (dirt in injector)

(Error at degree that it is not indicated)
Defective Bkup speed sensor or wiring harness

q Defective EGR valve
Defective Ne speed sensor or wiring harness

q Defective bypass valve

Low setting of low idle speed

Malfunction of bypass valve
Malfunction of EGR valve

Q Q Q Q Q
Questions
At a certain speed range

At low idle w Q Q Q Q Q Q Q
Engine hunts
Even when speed is raised Q Q Q Q Q
On slopes w Q Q
Filters have not been replaced according to Operation and Maintenance Manual w w
Check items
There are rust and water in fuel drained from fuel tank Q Q
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code q
Carry out troubleshooting according to "Bypass Valve Servo Error (*2)" indicated by q
code
Troubleshooting

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q q
change
Carry out troubleshooting according to "Eng Ne Speed Sensor Error (*3)" indicated by
q
code
Carry out troubleshooting according to "Eng Bkup Speed Sensor Error (*4)" indicated q
by code
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add

*2: Displayed failure code [CA1628] and [CA1629]
*3: Displayed failure code [CA689]
*4: Displayed failure code [CA778]
16 HM400-2
S-6 Engine lack output (or lacks power) 1

General causes why engine lacks output Causes
Defective installation of charge pressure sensor (air leakage)

q
q Defective spray condition of fuel
Defective fuel temperature sensor or wiring harness

Defective charge pressure sensor or wiring harness
Clogged injector or defective spray (dirt in injector)

q Overheating
Defective drive of injector (signal or solenoid)

o See "S-14 Coolant temperature becomes too

high (Overheating)"

q Control by controller in derate mode
Air leakage from air intake piping

(limiting injection rate (output) because of an
Leaking or clogged fuel piping


error in electrical system)

Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Filters have not been replaced according to Operation and Maintenance
Manual w
Engine oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
Exhaust gas is
Immediately after engine is started, temperature of exhaust manifold of a
cylinder is low w
When engine is rotated, interference sound comes out from around
w
Check items
turbocharger
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load
is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q

Inspect air intake piping directly q
Boost pressure is low q q q
Troubleshooting

Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)"
indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q q
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to "Chg Air Press Sensor High (Low)
Error (*2)" indicated by code q
Carry out troubleshooting according to "Fuel Temp Sensor High (Low) Error
(*3)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
*1: Displayed failure code [CA559] and [CA2249] Remedy

HM400-2 17
S-7 Exhaust gas is black (incomplete combustion) 1

General causes why exhaust gas is black Causes
q Insufficient intake of air
Leakage of air between turbocharger and cylinder head

q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

q Overheating

o See "S-14 Coolant temperature becomes too

high (Overheating)"
Clogged EGR gas pressure piping

Control by controller in derate mode

q
Improper fuel injection pressure

Improper fuel injection timing
(limiting injection rate (output) because of an
Crushed or clogged muffler
Clogged or seized injector

error in electrical system)
Abnormally worn injector

q EGR valve stuck open
(There is much EGR gas and intake of air is
Stuck EGR valve

insufficient)
q Clogged EGR gas pressure piping
(Exhaust gas is mixed in intake air during accel-
eration and deceleration)
Suddenly became black w Q Q Q Q
w w Q Q Q
Questions
Exhaust gas color Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head or clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
cylinder is low Q w
When engine is rotated, interference sound comes out from around
turbocharger w
Check items
When engine is rotated, abnormal sound comes out from around cylinder
head w
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
When spill hose from injector is disconnected, abnormally much fuel spills w

Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated
by code q
Inspect EGR gas pressure piping directly (*2) q
Troubleshooting

When muffler is removed, exhaust gas color improves q
Carry out troubleshooting according to "Rail Press (Very) Low Error (*3)"
indicated by code q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error
(*4)" indicated by code q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 HM400-2

*2: EGR gas pressure piping
Remove 2 EGR gas pressure pipes (2) and check their inside for clogging.

HM400-2 19
S-8 Oil consumption is excessive (or exhaust gas is blue) 1

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
Clogged breather or breather hose

Dust sucked in from intake system
Oil leakage from EGR valve stem

q External leakage of oil

Worn seal at turbocharger end
Worn or damaged rear oil seal
Oil leakage from oil drain plug

q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes dirty quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust gas is blue under light load Q w w
Excessive Q Q w w
Amount of blow-by gas
None w
There is dust in intake manifold q

Inside of intake manifold is abnormally dirty q
Play of turbocharger shaft is excessive q q
Troubleshooting
Exhaust port of EGR valve is dirty with oil q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q q
Oil leaks out of engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 HM400-2
S-9 Oil becomes dirty quickly 1

General causes why oil becomes dirty quickly Causes
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather or breather hose

q Use of improper oil

q Overload operation
Defective oil filter safety valve

Worn valve or valve guide
Exhaust gas color is bad

Worn EGR valve guide
Clogged oil cooler

Clogged oil filter
Questions

Non-specified fuel is used Q
Engine oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
(if monitor is installed)
There are metal particles in oil drained from oil pan Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Exhaust gas is
Black w
Comes out excessively Q Q w Q
Blow-by gas
Does not come out at all w
Play of turbocharger shaft is excessive q

Exhaust port of EGR valve is dirty with oil q
Troubleshooting
See S-7
Check breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
HM400-2 21
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
Leakage of fuel

q
q Defective condition of fuel injection (fuel pressure or injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective spray by injector

Malfunction of injector
E E E
Questions

Is large compared to other machines of same model Q Q Q Q
Fuel consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Black Q Q Q Q
Exhaust gas is
White Q
Remove head cover and inspect inside directly q

Inspect feed pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
When spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
q
code
Confirm with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

22 HM400-2
S-11 Oil is in coolant

(or coolant spurts back or coolant level goes down) 1
General causes why oil is in coolant Causes
q Leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting
Broken hydraulic oil cooler or power train oil cooler on

q Leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head or head gasket
Broken oil cooler core or O-ring

Crack in cylinder block
E E
Questions

Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator and coolant spurts back w w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w
When hydraulic oil or power train oil is drained, water flows out w
Carry out troubleshooting on

Leakage from cylinder head is detected by pressure test q

Troubleshooting
Inspect cylinder block and liner directly q q
Inspect cylinder liner directly q
Leakage from oil cooler is detected by pressure test q

Replace
Replace
Replace
Replace
Replace
Remedy
—
HM400-2 23
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage from, clogging, or wear of lubrication system
Defective oil pressure sensor or wiring harness

Leaking, crushed, or clogged hydraulic piping
q Defective oil pressure control
Defective oil level sensor or wiring harness

q Selection of oil by the temperature etc. specified in the
Operation and Maintenance Manual is not observed
q Deterioration of oil due to overheating
Clogged or broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Clogged strainer in oil pan
Defective EGR oil pump

Worn journal of bearing
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

E E E E
Questions

Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is used Q Q
Filters have not been replaced according to Operation and Maintenance Manual w
Indicates pressure drop at low idle w Q Q
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil lever drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking or crushed w w
Check items
Oil is milky or smells of diesel oil w

There are metal particles in oil drained from oil pan w
There are metal particles in oil drained from oil filter w Q Q
There are metal particles in oil filter q

Inspect oil pan strainer and pipe directly q q
Oil pump is heavy to rotate or it has play q
Troubleshooting
Valve spring of oil pump relief valve is fatigued or damaged q

See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged or oil leaks through it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to "Eng Oil Press Sensor High (Low) Error (*1)"
q
indicated by code
When oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
—
Add
*1: Displayed codes [CA135] and [CA141]
24 HM400-2
HM400-2 25
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) or defective seal
Defective seal of auxiliary equipment (pump and compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for "S-11 Oil is in

coolant"
Cracked EGR cooler (Entry of coolant)

Fuel leakage inside cylinder block
Broken oil cooler core or O-ring

Worn or damaged rear oil seal
Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions

Fuel consumption has increased w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, water drops from muffler Q Q
When radiator cap is removed and engine is run at low idle, abnormally many bubbles w Q
Check items
come out or coolant spurts back

Exhaust gas is white Q Q
Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant flows out w
Oil level in damper chamber on applicable machine side is low w
Oil level in hydraulic tank on applicable machine is low w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
q
(*1).
Remove and inspect head cover directly q
Troubleshooting
Inspect cylinder block and liner directly q q

Inspect rear oil seal directly q
Leakage from oil cooler is detected by pressure test q
Remove and inspect water pump directly q
Remove and inspect thermostat cover directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
26 HM400-2

HM400-2 27
S-14 Coolant temperature becomes too high (Overheating) 1

General causes why coolant temperature becomes too Causes
high
Rise of power train oil temperature on applicable machine side

q Lack of cooling air (deformation or damage of fan)

q Drop in heat dissipation efficiency
q Trouble in coolant circulation system
q Rise of oil temperature in power train
o Carry out troubleshooting on applicable machine
External leakage of coolant from EGR cooler

side
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Slipping fan belt or worn fan pulley

Clogged or crushed radiator fins
Clogged or broken oil cooler
Malfunction of thermostat
Clogged radiator core

Broken water pump
Low coolant level
Questions
Occurred suddenly Q Q w Q
Overheating
Has continued at low level Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates low (if monitor is installed) Q w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Fan pulley has play w
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back w
When light applied to radiator core, no light passes through w
Check items
Dirt and mud are accumulated in radiator shroud and undercover on applicable w w
machine side
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt squeaks under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant
temperature (if oil temperature gauge and coolant temperature gauge are w
installed)
Inspect EGR cooler for coolant leakage q

on applicable machine side
Carry out troubleshooting
Inspect cylinder liner directly q

Inspect oil cooler directly q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

Thermostat does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
Cracking pressure of radiator cap is low q
Inspect fan belt and pulley directly q
Coolant temperature is normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
28 HM400-2
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, or interference of fan belt

q Abnormal combustion
q Air sucked in from intake system
Leakage of air between turbocharger and cylinder head
Broken dynamic valve system (valve, rocker lever, etc.)

a Judge if the noise is an internal noise or an external
Interference of turbocharger or seized turbocharger

noise before starting troubleshooting.
Defective inside of muffler (Removal of bulkhead)

a The engine is operated in the low-temperature mode
Excessive wear of piston ring or cylinder liner

while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not
(Defective coolant temperature sensor)

Removed or seized gear train bushing
indicate abnormality, however
Cracked or leaking EGR gas piping

a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little

Improper gear train backlash
Clogged or seized injector

larger for up to about 5 seconds. This does not indi-

cate abnormality, however
Dirt caught in injector

Degree of use of machine Operated for long period E
Questions
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is used Q
There are metal particles in oil drained from oil filter w w
Air leaks between turbocharger and cylinder head w
When engine is rotated, interference sound comes out from around turbocharger w
When engine is rotated, abnormal sound comes out from around EGR gas w
piping
When engine is rotated, abnormal sound comes out from around cylinder head w w
When engine is rotated, beat noise comes out from around muffler w
Check items

cylinder is low w Q

Exhaust gas is
Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed q q
does not change
Abnormal noise comes out only at start of engine q
Confirm with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
HM400-2 29
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage, etc.)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and applicable machine
q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for "S-15 Abnormal noise is made", too
Stuck dynamic valve system (valve, rocker lever, etc.)
Broken parts in damper on applicable machine side

Loose engine mounting bolts or broken cushions
Worn main bearing or connecting rod bearing
Worn front support spigot joint

Improper gear train backlash
Improper injection timing

Worn camshaft bushing
E E E E
Questions

Suddenly increased Q Q
Vibration
Gradually increased Q Q Q Q
There are metal particles in oil drained from oil filter w w
There are metal particles in oil drained from oil pan w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at medium speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust gas is black w

Inspect main bearing and connecting rod bearing directly q
Inspect gear train directly q
Troubleshooting
Inspect camshaft bushing directly q

Confirm with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
Radial runout or facial runout is detected q
Inspect front support spigot joint directly q
Inspect inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
30 HM400-2
HM400-2 31

© 2009 KOMATSU
All Rights Reserved
32 HM400-2
SEN01442-03
HM400-2

HM400-2 2001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
List of adhesives ............................................................................................................................................. 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools .............................................................................................................................. 13
HM400-2 1
SEN01442-03 50 Disassembly and assembly
How to read this manual 1

(Rev. 2009.1)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In "Removal" section, the work procedures,
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1,•••X1 etc. and their parts the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is described are described as [1], [2] ••• etc. and their part
in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in "Removal" section
tuted and should always be used are explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a: Guidance or precautions for the work
2) Distinction of new and existing special tools
N: Tools newly developed for this [*1] : This mark shows that instructions or precau-
model. They have a new part num- tions for parts installation work are given in
ber respectively. "Installation" section.
R: Tools made available by redesign- 6 : Amount of oil or coolant to be drained
ing the existing tools which were
4 : Weight of part or component
developed for other models. Each
of them has a new part number
assigned by setting forward the Installation
part number of the existing tool.
q Unless otherwise instructed, installation of parts
Blank: Tools already available for other
is to be done in the reverse order to removal.
models. They can be used without
q Instructions and precautions for parts installa-
any modification.
tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in "Removal" section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of "Sketches of tion are described as [1], [2] ••• etc. and their
special tools". part numbers, part names and quantities are not
q Part No. of special tools starting with described.
79*T-***-****: q Marks shown in the "Installation" section stand
means that they are not available for the following.
from Komatsu Ltd. (i.e. tools to be
made locally). k : Precautions related to work safety
a: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
2 HM400-2
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1,•••X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] ••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market. a: Guidance or precautions for the work
2) Distinction of new and existing special tools 6: Amount of oil or coolant drained
N : Tools newly developed for this
model. They have a new part
number respectively. Assembly
R : Tools made available by redesign- q In "Assembly" section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2] ••• etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in "Assem-
3) Circle mark Q in sketch column: bly" section are as follows.
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of "Sketches of
special tools". a: Guidance or precautions for the work
2
q Part No. of special tools starting with : Type of coating material
79*T-***-****:
means that they are not available 3 : Tightening torque
5
from Komatsu Ltd. (i.e. tools to be : Amount of oil or coolant to be replenished
made locally).
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
HM400-2 3
List of adhesives 1
(Rev. 2008.11)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
Gasket sealant
tant sealant.
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 HM400-2
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum
• Used to lubricate linkages, bearings, etc.

lubricant
disulfide
• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the propeller shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
HM400-2 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease
• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 HM400-2
Special tool list 1

(Rev. 2009.1)
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity : t . . . . . . Special tools that cannot be substituted and should always be used
: q . . . . . . Special tools that will be useful if available and are substitutable with tools avail-
able on the market
a New/Remodel: N. . . . . . Tools newly developed for this model. They have a new part number respec-
tively.
: R. . . . . . Tools made available by redesigning the existing tools which were developed for
other models. Each of them has a new part number assigned by setting forward
the part number of the existing tool.
: Blank . . Tools already available for other models. They can be used without any modifi-
cation.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See "Sketch-
es of special tools")
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
1 795-630-5500 Standard puller t 1
Removal and installa- Removal of fuel supply
2 01010-81090 Bolt t 2
tion of fuel supply pump pump
3 01643-31032 Washer t 2
4 792-220-1110 Centering tool t 2 Centering of engine assem-
Removal and installa-
bly and transmission
tion of engine assembly 5 01050-61225 Bolt t 8 assembly
Removal and installa-
Adjustment of clearance in
tion of fuel injector and 6 795-125-1210 Thickness gauge t 1
crosshead
cylinder head
Removal and installa- Angle tightening of cylinder
7 790-331-1110 Angle tightening wrench t 1
tion of cylinder head A head bolt
8 795-931-1100 Seal puller t 1
795T-421-1210 Push tool t 1 Q
9 01050-31625 Bolt t 4
Removal and installa- 01050-31645 Bolt t 4

Removal front oil seal and
tion of front oil seal and 795T-421-1220 Push tool t 1 Q
rear oil seal
rear oil seal 10 01050-31625 Bolt t 4
01050-31645 Bolt t 4
795-521-1110 Push tool t 1
11
01050-31640 Bolt t 4
790-201-2210 Plate t 1
790-201-2740 Spacer t 1
791-600-1120 Bolt t 1
Disassembly, assembly 790-101-2540 Washer t 1 Press fitting of shaft
B 1
of output shaft 01580-01613 Nut t 1 bearing
01643-31645 Washer t 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Hydraulic pump t 1
HM400-2 7
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
790-101-5401 Push tool kit t 1
Disassembly, assembly 790-101-5431 • Plate 1
B 2 Press fitting of cage oil seal
of output shaft 790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-501-5000 Unit repair stand t 1 AC100V
Disassembly,
AC110V, assembly of
790-501-5200 Unit repair stand t 1
1 220V torque
790-901-2110 Bracket t 1 converter
assembly
792T-413-1110 Plate t 1 N Q
792-420-1110 Centering tool t 1
792-420-1120 • Flange 2 Centering of engine and
2
792T-413-1120 • Collar 1 torque converter
01050-31230 • Bolt 8
Removal, installation of
3 792-103-5110 Wrench t 1
pump bearing locknut
Disassembly, assembly Removal, installation of
C 4 790-102-1871 Nut wrench t 1
of torque converter PTO gear bearing set nut
Press fitting of pump
5 790-201-2730 Spacer t 1
bearing
Press fitting of stator shaft
6 793T-623-1170 Push tool t 1 N Q
bearing
7 792T-413-1120 Push tool t 1 N Q Press fitting of gear bearing
Press fitting of coupling
8 792T-413-1130 Push tool t 1 N Q
cover
790-101-5451 • Plate 1
9 Press fitting of cage oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-201-2750 Spacer t 1 Press fitting of shaft
1
790-201-2850 Spacer t 1 bearing
790-101-5461 • Plate 1
2 Press fitting of cage oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Press fitting of coupling
3 792T-415-1310 Push tool t 1 N Q
Disassembly, assembly cover
D
of transmission Check of operation of
4 799-301-1500 Oil leak tester kit t 1
clutch piston
792T-415-1320 Block t 2 N Q Disassembly of 2nd and
5
01010-81050 Bolt t 2 3rd clutch assembly
790-101-2501 Push puller t 1
790-101-2510 • Block 1 Pulling out of FH & 1st
6
790-101-2520 • Screw 1 clutch bearing inner case
790-101-2540 • Washer 1
8 HM400-2
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
790-101-2560 • Nut 2
790-101-2570 • Plate 4
Disassembly, assembly 790-101-2630 • Leg 2 Pulling out of FH & 1st
D 6
of transmission 790-101-2660 • Adapter 2 clutch bearing inner case
790-112-1180 • Nut 1
790-201-1320 Spacer t 1
790-201-2850 Spacer t 1 Press fitting of bevel pinion
1 790-201-2740 Spacer t 1 bearing (For R/F
790-201-2750 Spacer t 1 differential)

790-101-5481 • Plate 1 Press fitting of oil seal to
2
790-101-5421 • Grip 1 cage (For front differential)
01010-51240 • Bolt 1
For rear
790-201-2770 Spacer t 1
differential
Press fitting
3 For front of output
differential, shaft seal
792T-423-1130 Push tool t 1 N Q
R/F
differential
790-201-2740 Spacer t 1 Press fitting of shaft
4 792T-423-1110 Push tool t 1 N Q bearing (For front
792T-423-1120 Push tool t 1 N Q differential, R/F differential)
Press fitting of cage input
5 792T-423-1130 Push tool t 1 N Q
seal
Disassembly, assembly
H 792-103-0901 Wrench t 1
of axle Adjustment of preload on
6 792-222-1110 Adapter t 2
bearing
795-525-1000 Micrometer t 1
796-751-1500 Wrench assembly t 1 Measurement of turning
7
795-630-1803 Torque wrench t 1 torque of side gear
Press fitting of pin (for
8 792T-422-1250 Push tool t 1 N Q
differential assembly)
790-501-5000 Unit repair stand t 1 AC100V
Disassembly,
790-501-5200 Unit repair stand t 1 AC110, 220V assembly of
9
790-901-2110 Bracket t 1 differential
assembly
793-310-2141 Plate t 1 R Q
792T-422-1260 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
t 1 Press fitting of differential
10 790-101-5401 Push tool kit
lock gauge input seal
790-101-5471 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
HM400-2 9
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
792T-423-1140 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
Disassembly, assembly t 1 Press fitting of differential
H 11 790-101-5401 Push tool kit
of axle (R/F) gauge input seal
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
792T-422-1210 Fixture t 3 N Q For rear
Removal,
792T-427-1110 Fixture t 3 N Q For front installation of
1
01010-61435 Bolt t 3 brake
assembly
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 N Q
2 790-101-5421 Grip t 1 Press fitting of oil seal
01010-51240 Bolt t 1
Disassembly, assembly Press fitting of bearing to
J 3 792T-422-1230 Push tool t 1 N Q
of final drive and brake hub
Press fitting of bearing to
4 792T-422-1240 Push tool t 1 N Q
tube
792-520-2110 Installer t 1 For large
792-530-1600 Push tool t 1 diameter Fitting of
5
For small floating seal
790-434-1620 Installer t 1
diameter
6 793-520-1805 Brake tester t 1 Check for brake oil leakage
Disassembly, assembly 792-620-1001 Tire remover t 1 Removal of tire from wheel
R 1
of wheel 790-101-1102 Hydraulic pump t 1 assembly
792T-446-1110 Push tool t 1 N Q
Press fitting of bearing to
1 792T-446-1120 Push tool t 1 N Q
hitch frame
792T-446-1150 Push tool t 1 N Q
790-101-5461 • Plate 1 Press fitting of oil seal to
Disassembly, assembly 2
790-101-5421 • Grip 1 frame
of hitch frame
01010-51240 • Bolt 1
Q 792T-446-1130 Plate t 1 N Q
792T-446-1140 Plate t 1 N Q Press fitting of oil seal to
3
790-101-5421 Grip t 1 cage and frame
01010-51240 Bolt t 1
Disassembly, assembly 790-201-1881 • Push tool 1

4 Press fitting of roll bushing
of suspension 790-101-5021 • Grip 1
01010-50816 • Bolt 1
10 HM400-2
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
790-201-1690 • Plate 1
5 Press fitting of dust seal
790-101-5021 • Grip 1
Disassembly, assembly 01010-50816 • Bolt 1
Q
of suspension Suspension tool
792-610-1000 t 1
assembly
Filling with oil and nitrogen
6
792-610-1100 • Pump assembly 1 gas
792-610-1200 • Charging tool assembly 1
Disassembly, assembly 790-452-1100 Seal installer set t 1 Disassembly, assembly of
T 1
of steering valve 790-452-1200 Pilot ring tool t 1 steering valve
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of
1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
Removal, installation of
2 790-102-3802 Wrench assembly t 1
cylinder head
790-102-4300 Wrench assembly t 1 Removal, installation of
3 piston (For steering
790-102-4310 Pin t 2 cylinder)
790-720-1000 Expander t 1
796-720-1670 Ring t 1 Steering, No.
4 07281-01279 Clamp t 1 2 hoist Installation
796-720-1680 Ring t 1 For No. 1 of piston ring
07281-01289 Clamp t 1 hoist cylinder
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly, assembly • Push tool

U (Outside diameter: For steering Press fitting
of hydraulic cylinder 790-201-1811 1
5 135 mm, Inside diameter: cylinder of roll
130 mm, Length: 35 mm) bushing
For No. 1
790-201-1881 • Push tool 1
hoist cylinder
For No. 2
790-201-1841 • Push tool 1
hoist cylinder
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Plate
(Outside diameter of dust For steering Press fitting
6 790-201-1620 1
seal press fitting part: 146 cylinder of dust seal
mm)
For No. 1
790-201-1690 • Plate 1
hoist cylinder
For No. 2
790-201-1650 • Plate 1
hoist cylinder
HM400-2 11
New/remodel
Necessity
Sym-
Sketch
bol
Q’ty
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100V) t 1
Air connditioner Filling with air conditioer
1 799-703-1111 Vacuum pump (220V) t 1
assembly refrigerant (gas)
799-703-1121 Vacuum pump (240V) t 1
X 799-703-1401 Gas leak detecter t 1
Removal and installa- 2 793-498-1210 Lifter (suction cup) t 2
Removal of operator's cab
tion of operator's cab
3 20Y-54-13180 Stopper rubber t 2 glass
glass (stuck glass)
Operator's cab 4 792-454-1100 Pump assembly q 1
Charging accumulator with
Accumulator assembly Y 1 792-610-1700 Gas charge tool
gas
12 HM400-2
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.
A9 Push tool
A10 Push tool
HM400-2 13
C1 Plate
C6 Push tool
14 HM400-2
C7 Push tool
C8 Push tool
HM400-2 15
D3 Push tool
D5 Block
16 HM400-2
H3, H5 Push tool
H4 Push tool
HM400-2 17
H4 Push tool
H8 Push tool
18 HM400-2
H9 Plate
H10 Push tool
HM400-2 19
H11 Push tool
J1 Fixture
20 HM400-2
J1 Fixture
J2 Push tool
HM400-2 21
J3 Push tool
J4 Push tool
22 HM400-2
Q1 Push tool
Q1 Push tool
HM400-2 23
Q1 Push tool
Q3 Plate
24 HM400-2
Q3 Plate
HM400-2 25

© 2009 KOMATSU
All Rights Reserved
26 HM400-2
SEN01443-03
HM400-2

HM400-2 2001 and up

Engine and cooling system
Removal and installation of fuel supply pump................................................................................................. 2
Removal and installation of engine assembly ................................................................................................. 5
Removal and installation of cylinder head assembly .................................................................................... 13
Removal and installation of fuel injector assembly ....................................................................................... 26
Removal and installation of radiator assembly ............................................................................................. 32
Removal and installation of cooling assembly .............................................................................................. 36
Removal and installation of aftercooler ......................................................................................................... 40
Removal and installation of engine front seal ............................................................................................... 43
Removal and installation of engine rear seal ................................................................................................ 45
HM400-2 1
Removal and installation of fuel

supply pump 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 795-630-5500 Standard puller t 1
A 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2
4. Remove mounting nut (5). [*1]
Removal a Take care not to drop the nut in the gear
case.
1. Tilt up engine hood (1).
k Check that the engine hood is locked

securely.
5. Remove glow plug wiring harness (6) (light

blue).
2. Remove cover (2). 6. Remove belt cover (7).
3. Rotate the crankshaft forward to set the center

point (a) between stamps 2/5TOP and 3/4TOP
of damper (3) to pointer (4).
a At this time, check that the forcing tap of
the drive gear is set to the top bolt hole for
mounting cover (2). (If not, rotate the
crankshaft 1 more turn.)
a At this position, the key of the pump shaft
is rotated clockwise 15° from the top.
2 HM400-2
7. Disconnect connector (CN-ACRD) (8) of the 13. Remove fuel filter and head assembly (16).
receiver tank.
14. Remove oil level gauge (17), oil filler tube (18),
8. Remove the band and move receiver tank (9) and blow-by tube (19).
outward and fix it with wires.
9. Disconnect connector (CN-COMP) (10) of the

air conditioner compressor.
10. Remove bracket (11) and V-belt (12). [*2]
11. Remove air conditioner compressor (13) and

move it outward and fix it with wires.
15. Remove 2 high-pressure pipes (20) between

the common rail and supply pump. [*3]
16. Remove return tube (21) coming from the com-

mon rail. [*4]
12. Disconnect bypass valve connector (SBP) (14)

and EGR valve connector (SEGR) (15).
17. Remove EGR oil tube (22).
18. Remove return hose (23) coming from the fuel

supply pump.
19. Remove 3 connectors (24) of the fuel supply

pump.
HM400-2 3
20. Remove mounting bolts (26) and bracket (27) Installation

of fuel supply pump assembly (25).
a Screw in mounting bolts (26) by 2 – 3 q Carry out installation in the reverse order to
turns to prevent the pump from falling. removal.
q Tighten the bolts and pipings of the pump tem-
21. Set tools A1, A2 and A3 as shown below and porarily first and position the pipings accurately
tighten the center bolt of tool A1 to remove so that each part will not be installed forcibly
gear (32) from the shaft. and then tighten the bolts and pipings perma-
nently.
22. Remove mounting bolts (26) which were not
removed in the above step and fuel supply [*1]
3 Nut: 176 – 196 Nm {18 – 20 kgm}
pump assembly (25).
a If tool A1 is removed, the gear (32) falls.
Accordingly, do not remove tool A1 until [*2]
the pump is installed. For adjustment of the air conditioner compressor V-
belt, see Testing and adjusting "Adjusting air condi-
tioner compressor V-belt tension".
[*3]
3 Sleeve nut (Supply pump side):
39.2 – 49 Nm {4 – 5 kgm}
3 Sleeve nut (Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
[*4]
3 Plug: 17.7 – 22.6 Nm {1.8 – 2.3 kgm}
4 HM400-2
Removal and installation of 1. Open engine undercover (1).

engine assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
4 792-220-1110 Centering tool t 2
A
5 01050-61225 Bolt t 8
X 2 792-454-1100 Pump assembly q 1
Removal 2. Open engine hood (2).

lock knob.
chock the wheels.
and rear frame.
3. Remove radiator cap and then drain the cool-
q Precautions in tilting cab
k
ant.
When tilting the cab, check that the lock
a Location of drain valves
lever is fixed securely.
k
q Lower tank – 2 pcs
Do not start the engine while the cab is
q Oil cooler – 1 pc
tilted.
k When it is obliged to start the engine for 6 Coolant: 59 l
under the cab.
lever.
k Disconnect the cable from the negative (–)

terminal of the battery.
k If the coolant temperature in the radiator is
high, you may be scalded. In this case,
wait until the coolant temperature lowers
and then drain the coolant.
HM400-2 5
4. Sling operator's cab assembly (3) and tilt it up. 7. Crossbar, radiator tank and reservoir tank
a Use 2 shackles (S) so that hook (F) of the assembly
sling will not hit glass (G) of the cab 1) Remove coolant spill hose (6).
assembly.
5. Pull lock lever (2-1) and set lock bar (B) with
the care the direction of the lock bar (B).
k Check that the lock lever (2-1) closes
and the operator cab assembly (3) is
held securely in position by the lock
bar (B).
For details, see Testing and adjusting, Method
of tilting up cab.
a Pump assembly X2 is necessary for tilting
up by tilt cylinder.
2) Remove reservoir tank lower hose (7).
3) Remove hose (8) and connector (CN01)

(9).
6. Fuel filter, power train filter

Remove fuel filter (3) and power train filter (4)
from crossbar (5).
6 HM400-2
4) Remove hoses (10). 9. Remove the right aftercooler hose and pipe
5) Remove hose clamp (11). (16).
6) Remove crossbar (12), radiator tank (13) 10. Air conditioner compressor
and reservoir tank (14) as an assembly. 1) Remove glow plug wiring harness (17)
(light blue).
2) Remove belt cover (18).
8. Air cleaner
Remove air cleaner assembly (15).
3) Remove bracket (19) and V-belt (20). [*1]
4) Remove air conditioner compressor (21),
move it outward and fix it to the machine
with wires.
HM400-2 7
11. Exhaust pipe 13. Remove the left aftercooler hose • pipe (27)
1) Remove heat insulation plate (22) and and radiator hose (28).
heat insulation cover (23).
14. Remove fan guard (29).
2) Remove exhaust pipe (24).

15. Fan
Remove fan (31) from fan coupling (30).
a Leave the fan on the radiator side.
12. Air hose

1) Disconnect dust indicator connector (CN-
M11) (25).
2) Remove the air hose • pipe assembly (26). 16. Remove radiator lower hose (32).
17. Remove alternator front cover (33).
8 HM400-2
18. Remove alternator terminals (34) 3 places. 21. Wiring of starting motor
1) Remove wiring (37) of terminal B.
2) Disconnect connector (CN-78) (38) com-
ing from the alternator.
19. Remove heater hose (35) from the bottom of

the engine.
22. Remove 2 heater hose clamps (39) on the fly-

wheel housing.
20. Remove heater hose (36) from the top of the

engine.
23. Disconnect fuel hose (40) between the fuel

tank and air intake manifold.
a This hose is installed under the heater
hose.
HM400-2 9
24. Remove coupling yoke (41) of the output shaft 27. Disconnect engine controller connectors (J2F)
from the engine end. [*2] (44) and (J3P) (45).
25. Remove muffler bracket (42) from the right rear 28. Remove pump hose (46) on the left rear
engine mount. mount.
26. Disconnect oil level sensor connector (CNOL) 29. Remove hose (47) coming from the water
(43) on the left side of the oil pan. pump under the left front of the engine.
10 HM400-2
30. Engine mounting bolts Installation

1) Remove 2 front engine mounting bolts
(48), 1 piece each from the right and left. q Carry out installation in the reverse order to
removal.
[*1]
For adjustment of the air conditioner compressor V-
belt, see Testing and adjusting "Adjusting air condi-
tioner compressor V-belt tension".
[*2]
q When installing the drive shaft, check that the
key way of the spider cap is fitted in the key
way of the mating yoke, and then tighten the
mounting bolts.
2 Coupling yoke mounting bolt:
Adhesive (LT-2)
2) Remove 2 rear engine mounting bolts
(49), 1 piece each from the right and left. 3 Coupling yoke mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
3 Engine mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm}
q If the engine assembly, transmission and
torque converter assembly or drive shaft was
removed, align the engine and transmission in
the lateral direction.
1) Install tool A4 to the coupling on the
engine side and that on the torque con-
verter side.
2) Apply scales [1] to tools A4 on the right
31. Engine assembly and left sides.
Using sling [1], remove engine assembly (50). 3) Measure level differences (a) and (b)
[*3] between scales [1] and tools A4 on the
right and left sides.
4 : Engine assembly: 1,700 kg a Check that the largest level difference
on both sides is 3 mm or less.
(If each level difference is not even,
check that it is 3 mm or less at the
largest point.)
a If the level difference is larger than 3
mm, reduce it by moving the torque
converter and transmission assembly.
HM400-2 11
a When installing the drive shaft, check

that the key way of the spider cap is
fitted in the key way of the mating
yoke, and then tighten the mounting
bolts.
2 Coupling yoke mounting bolt:
Adhesive (LT-2)
a 3 Coupling yoke mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a While drive shaft (51) between the
engine and transmission is installed,
measure distance (c) between the fly-
wheel housing and coupling end.
If distance (c) is out of the following range,
set it into the following range by moving
the engine assembly or transmission and
front differential assembly.
Distance (c): 210.2 –0–3 mm
Refilling with coolant

q Add coolant up to the coolant filler of the radia-
tor. Run the engine to circulate the coolant
through the system. Then, check the coolant
level in the reservoir tank again.
Refilling with oil

q Add oil (EO30-CD) to the specified level.
12 HM400-2
Removal and installation of 3. Operator's cab and engine hood

1) Tilt up engine hood (1).
cylinder head assembly 1
Special tools securely.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
6 795-125-1210 Thickness gauge t 1
A Angle tightening
7 790-331-1110 t 1
wrench
Removal
k When tilting the cab, observe the following 2) Sling operator's cab assembly (2) and tilt it
precautions to prevent a serious injury or up.
fatal accident caused by fall of the cab. a Use 2 shackles (S) so that hook (F) of
k To prevent interference between the cab the sling will not hit glass (G) of the
and the dump body, set the steering in a cab assembly.
st raight ah ea d pos ition a nd stop the 3) Pull lock lever (2-1) and set lock bar (B)
machine on the level ground. with the care the direction of the lock bar
k Lock the dump lever with the dump lever (B).
lock knob. k Check that the lock lever (2-1)
k Turn the parking brake switch ON and closes and the operator cab
chock the wheels. assembly (2) is held securely in
k Set the lock bar to the frame and lock front position by the lock bar (B).
and rear frame. For details, see Testing and adjusting,
Method of tilting up cab.
q Precautions in tilting cab a Pump assembly X4 is necessary for
k When tilting the cab, check that the lock tilting up by tilt cylinder.
k Do not start the engine while the cab is
tilted.
k When it is obliged to start the engine for
under the cab.
lever.

1. Drain the coolant.
2. Engine undercover
Remove the engine undercover.
HM400-2 13
4. Air cleaner assembly 7. Remove the upper tank end of radiator upper
Remove air cleaner assembly (3). tank hose (7).
5. Remove plate (5) and hose assembly (4). 8. Crossbar above engine
1) Remove fuel prefilter assembly (8).
2) Remove transmission filter assembly (9).
6. Remove hose (6) between the turbocharger

and aftercooler.
3) Lift off crossbar (10) above the engine.
14 HM400-2
9. Remove exhaust pipe (11). 4) Remove bracket (15).

5) Remove 2 EGR pipes (16).
a Remove the EGR pipe and EGR
valve together.
10. Pipe between intake manifold and bypass

valve
1) Remove 2 heat insulation plates (12) of
the pipe between the intake manifold and 11. Turbocharger lubrication tube
bypass valve. 1) Remove turbocharger lubrication tube
2) Remove fan guard (13). (17).
3) Remove plate (14). 2) Remove turbocharger drain tube (18).
HM400-2 15
12. Remove EGR gas pressure tube (19). 2) Sling turbocharger • exhaust manifold
a This tube must be removed since it assembly (23) temporarily and then
becomes an obstacle when the No. 1 cyl- remove the mounting bolts and lift off the
inder head cover is removed. assembly. [*1]
13. Tube between exhaust manifold and EGR 15. Fuel filter head assembly
cooler 1) Remove 2 fuel tubes (24).
1) Remove heat insulation plate (20). 2) Remove fuel filter head assembly (25).
2) Remove tube (21) between exhaust mani-
fold and EGR cooler.
16. Remove hose and tube (26) between the after-

cooler and air inlet.
14. Turbocharger • exhaust manifold assembly
1) Remove bracket (22).
16 HM400-2
17. Oil filter head assembly 20. Remove priming pump (32).
1) Remove 2 oil filter head tubes (27).
2) Remove oil filter head assembly (28).
21. Remove priming pump bracket (33).
18. Remove blow-by tube (29).
22. Remove oil filter bracket (34).
19. Remove EGR solenoid connectors (30) and

(31).
23. Remove air intake connector (35).
HM400-2 17
24. Intake manifold 26. Remove common rail bracket (40), related
1) Remove 5 brackets (36). clamp (41) and 6 fuel high pressure tube (42).
[*3]
2) Remove 24 mounting bolts and lift off

intake manifold (37). [*2] 27. Remove fuel return tube (43). [*4]
25. Disconnect injector wiring harness (39) and 28. Remove coolant return (air bleeding) tube (44).
supply pump wiring harness (38) and move [*5]
them aside.
18 HM400-2
29. Cylinder head cover 31. Fuel injector [*8]

Remove the mounting bolts and each cylinder 1) Remove 2 nuts (51) of the solenoid valve
head cover (45). [*6] of fuel injector (50).
a Loosen nuts (51) alternately.
2) Pull out spring clamp (52).
3) Remove the bolts of clamp (53).
4) Remove bolt (56) and holder (55).
5) Push in connector (54) and remove the
injector wiring harness.
a An O-ring is fitted to connector (54).
30. Rocker arm and shaft assembly

1) Remove the 3 mounting bolts and rocker
arm and shaft assembly (46). [*7]
a Loosen locknut (48) and loosen
adjustment screw (49) 2 – 3 turns so
that an excessive force will not be
applied to push rod (47) when the
rocker arm is installed. 6) Loosen the bolts of holder (58) of fuel
injector (57).
7) Insert small L-shaped bar [1] under con-

nector (60) of fuel injector (59) and pry fuel
injector (59) out.
a Do not grip and pull out the solenoid
valve at the top of fuel injector (59)
with pliers etc.
HM400-2 19
32. Push rod [*9]

Remove push rod (61).
33. Cylinder head assembly and crosshead

1) Remove crosshead (62). [*10]
2) Remove mounting bolts (63), auxiliary
bolts and cylinder head (64). [*11]
3) Remove each cylinder head gasket.
20 HM400-2
Installation [*3]
1. Before installing the fuel high-pressure pipe,
q Carry out installation in the reverse order to check the following.
removal. If there is any defect, it can cause fuel leakage.
Accordingly, replace the fuel high-pressure
[*1] pipe.
a Tighten the bolts in the order shown in the fol- q Check the taper seal of the connecting
lowing figure. part (Part (a): Part of 2 mm from the end)
3 Turbocharger mounting bolt:
for visible lengthwise slit (b) and dent (c).
44.1 – 49 Nm {4.5 – 5.0 kgm} q Check part (d) (end of the taper seal: Part
a Tighten the exhaust manifold mounting bolts in at 2 mm from the end) for stepped-type
the following order. wear (fatigue) which your nail can feel.
1) Tighten bolts [1] – [3] in numeric order.
2) Tighten other bolts [4] – [24] in numeric order.
3 Exhaust manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2. Tighten sleeve nuts (1) and (2) of the fuel injec-

tor by 2 turns with the fingers and then tighten
them with a spanner.
a If a sleeve nut does not catch well, press
[*2] its end with another spanner and turn it
a Tighten the bolts in the order of [1] – [24]. with the spanner.
3 Air intake manifold mounting bolt:
a Tighten the sleeve nuts with spanner-type
58.8 – 73.5 Nm {6.0 – 7.5 kgm} torque wrench [1].
3 Sleeve nut for fuel high-pressure pipe:
39.2 – 49 Nm {4 – 5 kgm}
HM400-2 21
3. Tighten all of clamps (3), (4), (5) and (6) with [*6]
the fingers first and check that each part is not Fit the O-ring and install cylinder head cover (9).
installed forcibly and then tighten the clamps a Tighten the bolts at the front of the intake man-
permanently. ifold temporarily since they are also used to fix
a Install clamps (3), (4) and (5) after install- the wiring harness clamp.
ing the intake manifold. 3 Cylinder head cover:
3 Clamp bolt: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*7]
[*4] 1. Install rocker arm and shaft assembly (10) and
3 Fuel return tube joint bolt: tighten mounting bolts (11), (12) and (13).
9.8 – 12.7 Nm {1.0 – 1.3 kgm} a Note that the stem lengths of mounting
bolts (11), (12) and (13) are different.
Mounting bolt (11): 120 mm
Mounting bolt (12): 90 mm
Mounting bolt (13): 75.2 mm
a Check that the ball of the adjustment
screw is fitted to the socket of the push
rod securely.
3 Rocker arm mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
[*5]
3 Coolant return tube joint bolt (air bleeding):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
22 HM400-2
2. Adjust the valve clearance according to the fol- [*8]

lowing procedure. 1. Install the fuel injector according to the follow-
a Adjust the clearance between the cross- ing procedure.
head and rocker arm to the following val- a Check that there is not dirt in the injector
ues. sleeve.
a Valve clearance (when cold) 1) Install the gasket and O-ring to the fuel
Air intake valve: 0.35 ± 0.02 mm injector.
Exhaust valve: 0.57 ± 0.02 mm 2) Insert holder (21) in fuel injector (20) and
a Rotate the engine and adjust the valve then insert them together, directing injec-
clearance of each cylinder in the firing tor connector (24) toward the fuel high-
order of 1, 5, 3, 6, 2 and 4. pressure pipe insertion hole.
1) Rotate the crankshaft forward and set 3) Install the spherical washer to bolt (22)
stamped line of "1.6TOP" (e) on vibration and temporarily tighten holder (21).
damper (14) to pointer (15), watching the 2 Spherical washer:
movement of the valve. Engine oil (EO30)

4) Insert fuel high-pressure pipe sleeve (23)
through the fuel high-pressure pipe inser-
tion part, setting it to injector connector
(24), and tighten it temporarily.
a Tighten the sleeve nut on the com-
mon rail side, too, and take care that
the fuel high-pressure pipe will not
slant.
5) Tighten holder (21) permanently.
a While pulling the fuel high-pressure
pipe and fuel injector in the opposite
directions, tighten bolt (22).
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
2) Insert thickness gauge A6 between rocker a After tightening the holder, remove
arm (16) and crosshead (17) and tighten the fuel high-pressure pipe and install
adjustment screw (18) to a degree that the the other fuel injectors in order simi-
thickness gauge can be moved lightly. larly to the above.
3) Tighten locknut (19) to fix adjustment
screw (18).
3 Adjustment screw locknut:
53 – 64.7 Nm {5.4 – 6.6 kgm}
a After tightening the locknut, check the
valve clearance again.
HM400-2 23
[*9] [*11]
Install push rod (25). a Install the cylinder head according to the fol-
a Check that the push rod is fitted in the cam following procedure.
lower. 1. Check that the cylinder head mounting face
and inside of the cylinder are free from foreign
matter, and then set cylinder head gasket (27).
a When fitting the gasket, check that the
grommets are fitted correctly.
[*10]
1. Adjust the crosshead according to the follow-
ing procedure.
1) Loosen the locknut and return the adjust-
ment screw a little. 2. Before tightening the cylinder head mounting
2) While pressing the top of crosshead (26) bolts, check the following item.
lightly, tighten the adjustment screw. 1) Check the cylinder head mounting bolts.
3) After the adjustment screw touches the If they are out of the standard, do not use
valve stem, tighten it further by 20°. them but replace them.
4) Tighten the locknut. q Number of tightening times must be 6
3 Locknut: 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm} or less (Number of punch marks
denoting the number of tightening
times must be 5 or less).
q Stem length of bolt (Using limit) (b)
Short bolt: Less than 170.8 mm
Long bolt: Less than 205.8 mm
24 HM400-2
3. Install cylinder head assembly (29) and tighten a When not using tool A7, make marks (g)
mounting bolts (28) and auxiliary bolts. and (h) on the bolts and cylinder head with
2 Mounting bolt: paint, and then tighten the bolts by 90 +30°
+0
Molybdenum disulfide grease (LM-P) a After tightening bolts [1] – [6], tighten bolt
[7].
a After tightening each bolt, make a punch
mark on its head to indicate the number of
tightening times.
a When a new bolt is used, do not make a
punch mark on its head.
a Do not tighten each bolt more than 6 times
(The number of punch marks on its head
must be 5 or less).
3 Bolt [7]: 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
3 Mounting bolt:
a Tighten the mounting bolts in the order of
[1] – [6] as shown below.
1st time: 137 – 157 Nm {14 – 16 kgm}
2nd time:284 – 294 Nm {29.0 – 30.0 kgm}
3rd time: Using tool A7, tighten the bolts by
90 +30°
+0
HM400-2 25
Removal and installation of fuel 3. Operator's cab and engine hood

injector assembly 1
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
A6 795-125-1210 Thickness gauge t 1
X4 792-454-1100 Pump assembly q 1
Removal
k
2) Sling operator's cab assembly (2) and tilt it
To prevent interference between the cab
up.
and the dump body, set the steering in a a Use 2 shackles (S) so that hook (F) of
st raight ah ea d pos ition a nd stop the the sling will not hit glass (G) of the
machine on the level ground. cab assembly.
k Lock the dump lever with the dump lever 3) Pull lock lever (2-1) and set lock bar (B)
lock knob. with the care the direction of the lock bar
k Turn the parking brake switch ON and (B).
chock the wheels. k Check that the lock lever (2-1)
k Set the lock bar to the frame and lock front closes and the operator cab
and rear frame. assembly (2) is held securely in
position by the lock bar (B).
q Precautions in tilting cab For details, see Testing and adjusting,
k When tilting the cab, check that the lock Method of tilting up cab.
lever is fixed securely. a Pump assembly X4 is necessary for
k Do not start the engine while the cab is tilting up by tilt cylinder.
tilted.
under the cab.
lever.

26 HM400-2
4) Lift off crossbar (10) from the engine top. 5. Cylinder head cover
Remove the mounting bolts and each cylinder
head cover (31). [*2]
5) Remove EGR gas pressure tube (11).

a This tube must be removed since it
interferes with the No. 1 cylinder head 6. Rocker arm and shaft assembly
cover when the latter is removed. 1) Remove the 3 mounting bolts and rocker
arm and shaft assembly (32). [*3]
a Loosen locknut (34) and loosen
adjustment screw (35) 2 – 3 turns so
that an excessive force will not be
applied to push rod (33) when the
rocker arm is installed.
4. High pressure tube

Remove common rail bracket (28), related
clamp (29) and 6 fuel high pressure tubes (30).
[*1]
HM400-2 27
7. Fuel injector [*4] 7) Insert small L-shaped bar [1] under con-
1) Remove 2 nuts (37) of the solenoid valve nector (46) of fuel injector (45) and pry fuel
of fuel injector (36). injector (45) out.
a Loosen nuts (37) alternately. a At this time, move the high-pressure
2) Pull out spring clamp (38). pipe outward so that its taper seal will
3) Remove the bolts of clamp (39). not interfere with the injector.
4) Remove bolt (42) and holder (41). a Do not grip and pull out the solenoid
5) Push in connector (40) and remove the valve at the top of fuel injector (45)
injector wiring harness. with pliers etc.
a An O-ring is fitted to connector (40).
6) Loosen the bolts of holder (44) of fuel

injector (43).
28 HM400-2
Installation 3. Tighten all of clamps (3), (4), (5) and (6) with
the fingers first and check that each part is not
q Carry out installation in the reverse order to installed forcibly and then tighten the clamps
removal. permanently.
a Install clamps (3), (4) and (5) after install-
[*1] ing the intake manifold.
3 Clamp bolt:
1. Before installing the fuel high-pressure pipe,
check the following. 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
If there is any defect, it can cause fuel leakage.
Accordingly, replace the fuel high-pressure
pipe.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
[*2]
Fit the O-ring and install cylinder head cover (9).
a Tighten the bolts at the front of the intake man-
ifold temporarily since they are also used to fix
the wiring harness clamp.
3 Cylinder head cover:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2. Tighten sleeve nuts (1) and (2) of the fuel injec-

tor by 2 turns with the fingers and then tighten
them with a spanner.
a If a sleeve nut does not catch well, press
its end with another spanner and turn it
with the spanner.
a Tighten the sleeve nuts with spanner-type
torque wrench [1].
3 Sleeve nut for fuel high-pressure pipe:
39.2 – 49 Nm {4 – 5 kgm}
HM400-2 29
[*3] 2) Insert thickness gauge A6 between rocker

1. Install rocker arm and shaft assembly (10) and arm (16) and crosshead (17) and tighten
tighten mounting bolts (11), (12) and (13). adjustment screw (18) to a degree that the
a Note that the stem lengths of mounting thickness gauge can be moved lightly.
bolts (11), (12) and (13) are different. 3) Tighten locknut (19) to fix adjustment
Mounting bolt (11):120 mm screw (18).
Mounting bolt (12):90 mm 3 Adjustment screw locknut:
Mounting bolt (13):75.2 mm 53 – 64.7 Nm {5.4 – 6.6 kgm}
a Check that the ball of the adjustment a After tightening the locknut, check the
screw is fitted to the socket of the push valve clearance again.
rod securely.
3 Rocker arm mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
2. Adjust the valve clearance according to the fol-

lowing procedure.
a Adjust the clearance between the cross-
head and rocker arm to the following val-
ues.
a Valve clearance (when cold)
Air intake valve:0.35 ± 0.02 mm
Exhaust valve: 0.57 ± 0.02 mm
a Rotate the engine and adjust the valve
clearance of each cylinder in the firing
order of 1, 5, 3, 6, 2 and 4.
1) Rotate the crankshaft forward and set
stamped line of "1.6TOP" (e) on vibration
damper (14) to pointer (15), watching the
movement of the valve.
30 HM400-2
[*4]
1. Install the fuel injector according to the follow-
ing procedure.
a Check that there is not dirt in the injector
sleeve.
1) Install the gasket and O-ring to the fuel
injector.
2) Insert holder (21) in fuel injector (20) and
then insert them together, directing injec-
tor connector (24) toward the fuel high-
pressure pipe insertion hole.
3) Install the spherical washer to bolt (22)
and temporarily tighten holder (21).
2 Spherical washer:
Engine oil (EO30)
4) Insert fuel high-pressure pipe sleeve (23)
through the fuel high-pressure pipe inser-
tion part, setting it to injector connector
(24), and tighten it temporarily.
a Tighten the sleeve nut on the com-
mon rail side, too, and take care that
the fuel high-pressure pipe will not
slant.
5) Tighten holder (21) permanently.
a While pulling the fuel high-pressure
pipe and fuel injector in the opposite
directions, tighten bolt (22).
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the holder, remove
the fuel high-pressure pipe and install
the other fuel injectors in order simi-
larly to the above.
HM400-2 31

radiator assembly 1
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Removal
and the dump body, set the steering in a 2) Sling operator's cab assembly (2) and tilt it
st raight ah ea d pos ition a nd stop the up.
machine on the level ground. a Use 2 shackles (S) so that hook (F) of
k
the sling will not hit glass (G) of the
Lock the dump lever with the dump lever
cab assembly.
lock knob. 3) Pull lock lever (2-1) and set lock bar (B)
k Turn the parking brake switch ON and with the care the direction of the lock bar
chock the wheels. (B).
k
k Check that the lock lever (2-1)
Set the lock bar to the frame and lock front
and rear frame. closes and the operator cab
q Precautions in tilting cab assembly (2) is held securely in
k When tilting the cab, check that the lock position by the lock bar (B).
For details, see Testing and adjusting,
k Do not start the engine while the cab is a Pump assembly X4 is necessary for
tilted. tilting up by tilt cylinder.
under the cab.
lever.

32 HM400-2
4. Remove hose (3) between the turbocharger 8. Remove shroud (7), move it backward, and fix
and aftercooler. [*1] it.
5. Remove 3 reservoir tank hoses (4). 9. Lift off radiator upper cover (8).
6. Remove radiator upper hose (5). [*1] 10. Remove upper hose (9) between the right and
left radiators. [*1]
HM400-2 33
11. Remove lower hose (10) between the right and 14. Lift off right radiator (13).
left radiators.
12. Remove the hose and pipe assembly (11)

between the left radiator and lower tank.
13. Lift off left radiator (12).
34 HM400-2
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm}

HM400-2 35
Removal and installation of 6. Disconnect clamps (4).

cooling assembly 1
7. Remove water separator (5).
Removal
8. Remove bracket (6).
k Stop the machine on level ground.
k Turn the parking brake switch ON and stop 9. Remove tube • hose assembly (7). [*3]
the engine.
k Set the lock bar to the frame.
1. Open engine undercover.
2. Open engine hood (1).

securely.
10. Remove 4 reservoir tank hoses (8).
11. Remove radiator upper hose • tube assembly

(9). [*4]
3. Remove radiator cap and then drain the cool-

ant.
6 Coolant: 107 l
12. Remove cover (10).
4. Remove air cleaner (2). [*1]
5. Remove hose tube assembly (3) between the
turbocharger and aftercooler. [*2]
36 HM400-2
14. Remove shroud (12), move it backward, and a View after cooling assembly is removed
fix it.
For models other than EU specification model,

15. Remove fan assembly (13). fix air conditioner condenser (AC) with line [1]
to the grille, etc.
17. Disconnect radiator hose and tube assembly

(14). [*5]
a Remove radiator tube clamp.
16. Secure air conditioner condenser (AC) with

line [1] and disconnect air conditioner con-
denser (AC).
For the EU specification model, fix air condi-
tioner condenser (AC) with line [1] to sound 18. Remove nut (15). [*6]
absorbing blade (B).
19. Loosen nut (16) and disconnect rod (17). [*6]
20. Temporarily sling cooling assembly (18).

a Use mounting bracket (P) as a fulcrum.
21. Remove mounting bolts (19).
HM400-2 37
22. Lift off cooling assembly (18).

4 Cooling assembly: 280 kg
38 HM400-2
Installation [*4], [*5]

a Set the tightening portions of the 2 clamps on
q Carry out installation in the reverse order to the exactly opposite side to each other so that
removal. they can be tightened from the same direction.
(See [*2])
3 Radiator hose clamp:
[*1]
3 Air hose clamp: 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
9.8 ± 0.5 Nm {1.00 ± 0.05 kgm}
Positions of hose clamps [*6]
q B: Bulge Adjust the dimension so that the interval between
q C: Clamp fan and shroud may become 15 ± 5 mm over all
q H: Hose surroundings.
3 Nuts: 162 – 200 Nm {16.5 – 20.5 kgm}
q T: Tube
a Between hose end and outside clamp:
5 – 10 mm Refilling with coolant
q Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant: 107 l
[*2], [*3]
3 Air hose clamp:
9.8 ± 0.5 Nm {1.00 ± 0.05 kgm}
a If there are 2 clamps, set their tightening por-
tions on the exactly opposite side to each other
so that they can be tightened from the same
direction.
Positions of hose clamps
q B: Bulge
q C: Clamp
q H: Hose
q T: Tube
a Between bulge and inside clamp: Max. 5 mm
a Between hose end and outside clamp:
5 – 10 mm
HM400-2 39

aftercooler 1
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Removal
k
cab assembly.
k
under the cab.
lever.

1. Drain the coolant

a The coolant must be drained since the
upper hose between the right left radiators
will be removed.
2. Engine lower cover

Remove the engine lower cover.
40 HM400-2
4. Remove hose (3) between the turbocharger 7. Lift off aftercooler (6).
and aftercooler. [*1]
5. Remove upper hose (9) between the right and

left radiators. [*1]
6. Remove aftercooler mounting bolts (5), 2

pieces each from the right and left sides.
HM400-2 41
Installation
removal.
[*1]
3 Hose clamp: 10.5 ± 0.5 Nm {107 ± 5 kgm}

42 HM400-2
Removal and installation of Removal with tool A8

engine front seal 1 1) Drill several holes about 3 mm in diameter into
front seal (2).
Special tools 2) Set tool A8 to the drilled hole. (Tip: Drill type)
3) Remove the front seal with impacts of slide
New/Remodel
hammer (SH).
a Remove all the chips.
Necessity
Sym-
Part No. Part name
Tool A8
Sketch
bol q
Q'ty
8 795-931-1100 Seal puller t 1
A 795-521-1110 Push tool t 1
11
01050-31640 Bolt t 3
Removal
1. Remove the fan and fan shroud assembly. For
details, see "Removal and installation of cool-
ing assembly".
2. Remove inside 6 mounting bolts and pulley

and damper assembly (1).
a Since there are stamps on damper (1),
make a match mark (M) on it and the front
Installation
cover. 1. Install front seal (2).
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft.
a Never remove inside plastic cylinder (6) of
the replacement seal before installing the
seal.
3. Remove front seal (2).
HM400-2 43
1) Set large inside diameter side (b) of plas- 4) Tighten the bolts of tool A11 evenly to
tic inside cylinder (6) to the end of crank- press fit seal (2) until the end of tool A11
shaft (5). reaches the end of crankshaft (5).
a Take care not to mistake the direction a Seal driving distance (a) from crank-
of the plastic inside cylinder. shaft: 9.1 – 10.1 mm
a When press fitting the seal (2), take
care not to damage the lip of the seal
(2) with the tool set etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
2) Hold the metal ring of front oil seal (2) with

both hands and push it in evenly as if you
are passing over the large inside diameter
side of plastic inside cylinder (6).
3) After pushing in the seal, remove plastic
inside cylinder (6). 2. While setting match mark (M), install pulley
a When removing the inside cylinder, and damper assembly (1) and tighten the
take care not to damage the seal lip. mounting bolt.
3 Mounting bolt:
245 – 308.7 Nm {25 – 31.5 kgm}
44 HM400-2
Removal and installation of 1) Before pulling out rear seal (2), drive in it a
engine rear seal 1 little to separate it from the flywheel hous-
ing.
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
7 790-331-1110 Wrench (Angle) q 1
8 795-931-1100 Seal puller t 1
795T-421-1210 Push tool t 1 N Q
9 01050-31645 Bolt t 4
A
01050-31625 Bolt t 4
795T-421-1220 Push tool t 1 N Q
2) If the seal is sleeved, cut and remove
10 01050-31625 Bolt t 4
sleeve (5) with a chisel and a hammer.
01050-31645 Bolt t 4 a When cutting, take care extremely not
to damage crankshaft (4).
Removal 3) Hitch the end of tool A8 to the metal ring
of rear seal (2) and pull out the seal with
1. Remove the out put shaft assembly. impacts of slide hammer (SH).
For details, see "Removal and installation of a Do not use a drill etc. since chips may
out put shaft assembly". enter the engine.
a If chips were made, remove all of
2. Remove 1 mounting bolt of flywheel (1) and them.
install guide bolt. q Tool A8
3. Using eyebolt [1] (12 mm, P = 1.75), sling fly-

wheel (1) temporarily and remove the 8 mount-
ing bolts.
4. Move flywheel (1) toward this side and lift it off.

k Since the socket part of the flywheel is
shallow, it may fall suddenly. Take care
not to catch your fingers in the fly-
wheel.
4 Flywheel: 65 kg
a Left: Standard seal, Right: Sleeved seal
5. Remove rear seal (2) according to the follow-

ing procedure.
a Measure the distance from the end of the
housing.
HM400-2 45
Installation 1. Procedure for installing standard seal

a When installing rear seal (2), do not apply
a Check the Teflon seal (Laydown lip seal) by oil or grease to the shaft and seal lip.
checking the wear of the crankshaft and 1) Set large inside diameter side (b) of plas-
replace it with the "standard seal" or "sleeved tic inside cylinder (3) of rear seal (2) to the
seal". end of crankshaft (4).
If the shaft is worn to the degree of luster (If a Take care not to mistake the direction
wear which you feel with your finger is less of the plastic inside cylinder.
than 10 mm) and does not have any flaw, install
standard seal (A). In other cases, install
sleeved seal (B).
a (3): Plastic inside cylinder which is also
used as installation guide.
a (5): Sleeve.
a Do not remove installation guide (3) from
rear seal (2) before installing the rear seal.
a Handle rear seal (2) and sleeve (5) as an
assembly and never separate them from
each other.
q Standard spare seal q Sleeved seal
2) Hold the metal ring of rear oil seal (2) with

both hands and push it in evenly.
3) After pushing in the seal, remove plastic
inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
a Clean, degrease, and dry the seal surface

on the flywheel housing side.
a Clean, degrease, and dry the seal lip sur-
face (periphery of the crankshaft).
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust.
46 HM400-2
4) Tighten the 3 bolts evenly to press fit rear 2) Set sleeve (5) of the rear seal to the end of
seal (2) until the end of tool A9 (for press crankshaft (4) and tighten the 3 bolts
fitting the seal) reaches the end of crank- evenly to press fit sleeve and rear seal
shaft (4). assembly (6) until the end of tool A10
a Tighten tool A9 (for press fitting the reaches the end of crankshaft (4).
seal) first until it reaches the bolt (45 a Tighten tool A10 (for press fitting the
mm) and then tighten the bolt (25 sleeved seal) first until it reaches the
mm). bolt (45 mm) and then tighten the bolt
a When press fitting the seal, take care (25 mm).
not to damage the lip on the PTO side
with the tool set etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
3) Remove tool A10 (for press fitting the

sleeved seal) and install tool A9 (for press
fitting the seal).
4) Tighten the 3 bolts evenly to press fit
2. Procedure for installing sleeved seal sleeve and rear seal assembly (6) until the
a When installing the rear seal, do not apply end of tool A9 (for press fitting the seal)
oil or grease to the shaft and sleeve inside reaches the end of crankshaft (4).
cylinder surface (C). a Tighten tool A9 (for press fitting the
1) Set sleeve and rear seal assembly (6) to seal) first until it reaches the bolt (45
tool A10 (for press fitting the sleeved mm) and then tighten the bolt (25
seal). mm).
2 Sleeve inside cylinder surface (C): a After press fitting the seal, remove the
Gasket sealant (LG-7) red sealant layer from its periphery.
a Rear seal driving depth: 13.2 ± 0.2
mm from end of crankshaft
a When installing, set the dowel pin of

the crankshaft to the dowel hole of
the flywheel.
HM400-2 47
3. Flywheel a After tightening, make 1 punch mark (g) on

Using eyebolt [1] (12 mm, P = 1.75), sling fly- each bolt head to indicate the number of tight-
wheel (1), install it to the crankshaft, and ening time.
tighten the bolts.
a If there are 5 punch marks on a bolt, do
not use that bolt but replace it.
2 Threads and seat of bolt:
Engine oil SAE No. 30
4 Flywheel: 65 kg
a After installing the flywheel, measure the facial

runout and radial runout with tool [1].
a Radial runout: Max. 0.13 mm
a Facial runout: Max. 0.20 mm
a Tighten the mounting bolts according to the fol-

lowing procedure.
3 Flywheel mounting bolts
1st time: 118 ± 4.9 Nm {12 ± 0.5 kgm}
2nd time: 1) When using tool A7 (See the
tools list)
Retighten each bolt by 90° +30°+0 in
the order of [1] – [8].
2) When not using tool A7
Make marks (f) on each bolt and
flywheel with paint, then retighten
each bolt by 90° +30°
+0 in the order
q Carry out the following installation in the
of [1] – [8].
reverse order to removal.
48 HM400-2
HM400-2 49

© 2009 KOMATSU
All Rights Reserved
50 HM400-2
SEN01444-03
HM400-2

HM400-2 2001 and up

Power train, Part 1
Removal and installation of output shaft assembly ......................................................................................... 2
Disassembly and assembly of output shaft assembly .................................................................................... 6
Removal and installation of transmission and front differential assembly....................................................... 9
Disconnection and coupling of front differential and transmission ................................................................ 17
Disassembly and assembly of torque converter assembly ........................................................................... 18
Disassembly and assembly of transmission assembly ................................................................................. 26
HM400-2 1
Removal and installation of k Disconnect the cable from the negative (–)
output shaft assembly 1 terminal of the battery.
k Loosen the hydraulic oil filler cap to release
Special tools the internal pressure of the hydraulic tank.
New/Remodel
1. Drain the oil from the hydraulic tank.
6
Necessity
Sym- Hydraulic tank: 120 l
Part No. Part name
Sketch
bol
Q'ty
2. Open engine hood (1).
790-201-2210 Plate t 1
790-201-2740 Spacer t 1
791-600-1120 Bolt t 1
790-101-2540 Washer t 1
B 1 01580-01613 Nut t 1
01643-31645 Washer t 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
792-420-1110 Centering tool t 1
792-420-1120 • Flange 2
C 2
792T-413-1120 • Collar 1 3. Sling operator's cab assembly (32) and tilt it
01050-31230 • Bolt 8 up.
a Use 2 shackles (S) so that hook (F) of the
sling will not hit glass (G) of the cab
assembly.
Removal
k When tilting the cab, observe the following 4. Pull lock lever (31) and set lock bar (30) with
precautions to prevent a serious injury or the care the direction of the lock bar (30).
fatal accident caused by fall of the cab. k Check that the lock lever (31) closes
k To prevent interference between the cab and the operator cab assembly (32) is
and the dump body, set the steering in a held securely in position by the lock
st raight ah ea d pos ition a nd stop the bar (30).
machine on the level ground. For details, see Testing and adjusting, Method
k Lock the dump lever with the dump lever of tilting up cab.
lock knob. a Pump assembly X4 is necessary for tilting
k Turn the parking brake switch ON and up by tilt cylinder.
chock the wheels.
and rear frame.
k When tilting the cab, check that the lock
tilted.
under the cab.
lever.
2 HM400-2
2) Lift off hoist and steering pump assembly

(9).
4 Hoist and steering pump assembly:
45 kg
5. Vertical main bar

Remove vertical main bar (2).
4 Vertical main bar: 45 kg
7. Brake cooling and differential lock pump

(machine with differential lock)
1) Disconnect suction hose (10) and (11) and
discharge hoses (12) and (13).
6. Hoist and steering pump

1) Disconnect suction pipes (3) and (4) and
hoses (5), (6), and (7).
2) Lift off brake cooling and differential lock

pump assembly (14).
4 Brake cooling and differential lock
pump assembly:
30 kg (Machine with differential lock)
20 kg (Machine with limited slip differential)
HM400-2 3
8. Drive shaft between engine and transmis- 10. Output shaft cover
sion Remove snap ring (19), then remove cover
Remove guard bracket (15) from the output (20) by using forcing screw [1] and guide bolt
shaft cover and disconnect drive shaft (16) [2]. [*3]
between the engine and transmission. [*1]
4 Drive shaft between engine and trans-
mission: 55 kg
11. Output shaft

Using forcing screw [1] and guide bolt [2],
remove output shaft (21). [*4]
9. Coupling and oil seal cage 12. Bearing

Remove coupling (17) and oil seal cage (18). Remove bearing (22). [*5]
[*2]
4 HM400-2
Installation [*3]
q Carry out installation in the reverse order to 1) Sling cover (20).
removal. 2) Set tool B1 to the output shaft.
3) Using tool B1, press fit the inner race of the
[*1] bearing of cover (20) to the output shaft to
q When installing the drive shaft, check that the install cover (20).
key way of the spider cap is matched to that of
the mating yoke and tighten the bolts.
a Using tool C2, align the engine and torque con-
verter with each other.
[*4]
2 Output shaft mounting bolt: Adhesive (LT-2)
3 Output shaft mounting bolt:
98.0 – 123.0 Nm {10 – 12.5 kgm}
2 Mounting bolts of drive shaft between engine
and transmission: Adhesive (LT-2) [*5]
3 Mounting bolts of drive shaft between engine 2 Bearing: Apply ENS grease to all inside
and transmission: surface of bearing and outside
98 – 123 Nm {10 – 12.5 kgm} surface of shaft.
[Target: 113 Nm {11.5 kgm}]
For the procedure for supplying ENS grease, see

"Disassembly and assembly of output shaft assem-
bly".
[*2]
2 Spline: ENS grease
a Before using ENS grease, remove all other
grease completely. Do not mix ENS grease
with other grease. (Use different grease guns
for each type of grease.)
a ENS grease Part No.: 427-12-11871 (2kg can)
2 Bearing cover mounting bolt:
Adhesive (LT-2)
3 Bearing cover mounting bolt:
98.0 – 123.0 Nm {10 – 12.5 kgm}
HM400-2 5
Disassembly and assembly of output shaft assembly 1
Disassembly
1. Oil cage assembly
Remove oil seal (1) from cage (2).
2. Cover assembly
Remove bearing (3) from cover (4).
3. Damper assembly (5)

1) To keep the balance when reassembling,
mark the set positions of flange (6), body
assembly (7), and outer body (9) before
disassembling.
2) Remove body assembly (7) and rubber (8)
from outer body (9).
3) Remove bearing (10) from flywheel.
6 HM400-2
Assembly 7. Install cage assembly to cover assembly.

2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
1. Using push tool, press fit bearing (10) in fly-
wheel. 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
2 Flywheel hole portion, inside of bearing:
ENS grease
2. Assembly of damper assembly

1) Coat mating surface of outer body (9) and
one side of flange (6) with adhesive, then
assemble.
2 Mating surface of flange:
Adhesive (LG-6)
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
2) Install body assembly (7).

3) Assemble rubber (8).
a Before assembling, coat with grease.
2 Outer body, body assembly, rubber:
Grease (G2-LI)
4) Install flange (6).
2 Mating surface of flange:
Adhesive (LG-6)
2 Mounting bolt:
Thread tightener (LT-2)
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
a Align the marking position of the outer
body, body assembly flange, then
assemble.
3. Install damper assembly (5) to flywheel.

2 Shaft spline of body assembly:
ENS grease
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
4. Press fit bearing (3) in cover (4).

2 Bearing: ENS grease
5. Install cover assembly to flywheel.

4 Cover assembly: 35 kg
6. Assemble oil seal (1) in cage (2).

2 Oil seal: ENS grease
HM400-2 7
q Procedure for filling with ENS grease

1) ENS grease Part No.: 427-12-11871
2) Places to fill grease, amount of ENS-
grease (total amount: approx. 225g), and
places to coat with grease.
a: 60% pack (30g)
b: Coat all surfaces of bearing inner dia. and
shaft outer dia.
c: Fill 3 points in 20 mm width on circumference
at labyrinth.
d: 60% pack (30g)
e: B-B (R)
f : Full pack (35g)
g: Fill between grease lip and dust lip
h: 50% pack (30g)
i : Full pack (20g)
j : Coat all spline.
k: Full pack (25g)
l : Full pack (30g)
m: 90% pack (25g)
8 HM400-2
Removal and installation of 1. Discharging the air conditioner gas. [*1]

transmission and front differential
assembly 1
3. Drain the hydraulic oil and transmission oil.
Special tools
4. Lower the transmission undercover. (Do not
New/Remodel
disconnect it from the hinge.)
Necessity
Sym-
Part No. Part name
Sketch
bol
5. Tilting up operator's cab
Q'ty
1) Tilt the engine hood forward and fix it.
792-420-1110 Centering tool t 1 2) Sling operator's cab assembly (32) and tilt
792-420-1120 • Flange 2 it up.
C 2 a Use 2 shackles (S) so that hook (F) of
792T-413-1120 • Collar 1
01050-31230 • Bolt 8
cab assembly.
X 4 792-454-1100 Pump assembly q 1 3) Pull lock lever (31) and set lock bar (30)
with the care the direction of the lock bar
Removal (30).
k Check that the lock lever (31)
k When tilting the cab, observe the following closes and the operator cab
precautions to prevent a serious injury or assembly (32) is held securely in
fatal accident caused by fall of the cab. position by the lock bar (30).
k To prevent interference between the cab For details, see Testing and adjusting,
and the dump body, set the steering in a Method of tilting up cab.
st raight ah ea d pos ition a nd stop the a Pump assembly X4 is necessary for
machine on the level ground. tilting up by tilt cylinder.
lock knob.
chock the wheels.
and rear frame.
tilted.
under the cab.
lever.

HM400-2 9
6. Joint connectors between cab and vehicle 11. Operator's cab assembly
body Pull mounting pins (6) on both sides of the rear
Disconnect joint connectors (2) 10 places section outward and lift off operator's cab
between the cab and vehicle body. assembly (7). [*2]
a Before disconnecting, make match marks. a Loosen the muffler cover mounting bolts
and shift the muffler cover so that the
7. Brake hoses (on brake valve side) mounting pin will not interfere with it.
Disconnect brake hoses (3) 5 pieces (on the a Do not remove the pins, but just move
brake valve side). them outward.
a Before disconnecting, make match marks. 4 Operator's cab assembly: 1,300 kg
a Before removing the clamps, check the
positions of the hoses.
8. Steering hoses
Disconnect steering hoses (5) 5 pieces.
a Before disconnecting, make match marks.
9. Heater hoses
Disconnect heater hoses (4) 2 pieces.
a Before disconnecting, make match marks.
10. Operator's cab lift cylinder

Remove the connecting pin on the cab side
and disconnect operator's cab lift cylinder (62).
12. Transmission rear brake hoses

1) Disconnect right rear brake hoses (8)
(Upper side: 4 pieces, Lower side: 2
pieces).
10 HM400-2
2) Disconnect right rear brake hoses (9) and 14. Frame and hose assembly
(10). Remove frame and hose assembly (14).
3) Disconnect left rear brake hoses (11) and 15. Centralized connectors between vehicle
(12). body and engine
(Section above transmission) Remove top cover (15) and disconnect central-
ized connectors (16) and (17) between the
vehicle body and engine.
13. Vertical main bar

Remove vertical main bar (13).
4
16. Steering pipes and hoses
Vertical main bar: 45 kg.
Disconnect steering hoses (18) – (22) and
remove orifice (23).
HM400-2 11
17. Centralized oil pressure pickup hoses 19. Hoist and steering pump
Disconnect centralized oil pressure pickup 1) Disconnect suction pipes (31) and (32)
hoses (24) 4 pieces. and hoses (33), (34), and (35).
18. Intermediate connectors, torque converter 2) Lift off hoist and steering pump assembly
oil pressure sensor connector, exhaust (37).
4
brake hoses, and brake oil drain hose
Hoist and steering pump assembly:
1) Disconnect intermediate connectors (CN-
45 kg
DT1) (25), (CN-DT2) (26), and (CN-DT3)
(27).
20. Brake cooling and differential lock pump

(machine with differential lock)
2) Disconnect torque converter oil pressure
1) Disconnect suction hose (38) and (39) and
sensor connector (28), exhaust brake
discharge hoses (40) and (41).
hoses (29) 2 pieces, and brake oil drain
hose (30).
(Section above front of transmission)
12 HM400-2
2) Lift off brake cooling and differential lock 22. Torque converter and transmission charge
pump assembly (42). (machine with differ- pump hoses, differential lock hoses, brake
ential lock) hoses, and brake cooling hoses
4 Brake cooling and differential lock 1) Disconnect torque converter and trans-
pump assembly: mission charge pump hoses (45) and (46),
differential lock hoses (47) – (49) (only
30 kg (Machine with differential lock)
machine with differential lock), and brake
20 kg (Machine with limited slip differential) cooling hose (50).
2) Disconnect brake hoses (51) and (52).
21. Drive shaft between engine and transmis-

sion
Remove guard bracket (43) from the output
shaft cover and disconnect drive shaft (44)
between the engine and transmission. [*3]
4 Drive shaft between engine and trans-
mission: 55 kg.
(Section under front of transmission)
3) Disconnect brake cooling hoses (53) and

(54).
(Section under left rear of transmission)
HM400-2 13
23. Subtank pipe (Tank for brake) 26. Drive shafts on both sides (between front
Disconnect subtank (tank for the brake) pipe differential and front final drive)
(55). Disconnect drive shafts (58) on both sides
a Remove the pipe coupling. (between front differential and front final drive)
from the front differential. [*5]
24. Transmission rear mount grease tube

Disconnect rear mount grease tube (56) from 27. Transmission and front differential assem-
the rear mount. bly
Remove mounting bolts (59) (Front side: 4
pieces) and (60) (Rear side: 8 pieces) and lift
off transmission and front differential assembly
(61). [*6]
4 Transmission and front differential assem-
bly: 2,100 kg
25. Drive shaft between transmission and hitch

frame
Remove the guard and disconnect drive shaft
(57) between the transmission and hitch frame
from the transmission. [*4]
14 HM400-2
Installation [*4]
q Carry out installation in the reverse order to q When installing the drive shaft, check that the
removal. key way of the spider cap is matched to that of
[*1] 2 Mounting bolts of drive shaft between trans-
q Add refrigerant (R134a). mission and hitch frame: Adhesive (LT-2)

3 Mounting bolts of drive shaft between trans-
[*2] mission and hitch frame:
q Standard clearance (a) for operator's cab mount- 157 – 198 Nm {16 – 20 kgm}
ing pin: 0.2 mm (on each side) [Target: 177 Nm {18 kgm}]
[*5]
2 Mounting bolts of drive shafts on both sides
(between front differential and front final
drive): Adhesive (LT-2)
3 Mounting bolts of drive shafts on both sides
(between front differential and front final
drive): 98 – 123 Nm {10 – 12.5 kgm}
[*6]
q Standard shim thickness (b) for front mounting
[*3] bolt: 1 mm
q When installing the drive shaft, check that the q Standard shim thickness (c) for rear mounting
key way of the spider cap is matched to that of bolt: 2 mm.
a Using tool C2, align the engine and torque con-
verter with each other.
3 Front mounting bolt:

1,150 – 1,440 Nm {118 – 147 kgm}
3 Rear mounting bolt:
2 Mounting bolts of drive shaft between engine 171.5 – 214.5 Nm {17.5 – 21.9 kgm}
and transmission: Adhesive (LT-2)
3
k
Mounting bolts of drive shaft between engine After installing, bleed air from the brake cir-
and transmission: cuit. For details, see Testing and adjusting,
98 – 123 Nm {10 – 12.5 kgm} "Bleeding air from brake circuit".
HM400-2 15

Refilling with oil

q Add engine oil (specified oil) to the specified
level.
q Add transmission oil (specified oil) to the spec-
ified level.
q Supply the front differential case with specified
oil to the specified level.
16 HM400-2
Disconnection and coupling of

front differential and
transmission 1
Disconnection
1. Piping
Remove hose and piping (1).
2. Torque converter and transmission assem-

bly and brake pump
Remove the torque converter and transmission
assembly and brake pump (2).
4. Front differential assembly
Lift off front differential assembly (5). [*2]
4 Front differential assembly: 450 kg
Coupling
[*1]
Adjust the speed sensor. For details, see "Testing
and adjusting."
[*2]
2 Front differential mounting bolt:
3. Front output shaft speed sensor of trans- Adhesive (LT-2)
4
mission
Front differential mounting bolt:
Remove cover (3) and speed sensor (4). [*1]
490 – 608 Nm {50 – 62 kgm}
HM400-2 17
Disassembly and assembly of 2) Place torque converter housing (3) on

torque converter assembly 1 block [3] with the pump side down.
3) Remove mounting bolts (2) left in step 1)
Special tools above. Using eyebolt [4], remove torque
converter assembly (4).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1
C 790-901-2110 Bracket t 1
792T-413-1110 Plate t 1 N Q
3 792-103-5110 Wrench t 1
Disassembly
1. PTO assembly 3. Turbine and clutch assembly
Using eyebolt [1], tighten forcing screw [2] to 1) Set torque converter assembly (4) to tool
remove PTO assembly (1). C1.
2. Torque converter assembly 2) Remove mounting bolts (5) on the pump

1) Loosen all mounting bolts (2) and remove side.
them, leaving 3 of them.
18 HM400-2
3) Using eyebolt [5], remove turbine and 2) Using puller [6], remove inner race (9) and
clutch assembly (6). pump assembly (10).
a For further disassembly, see "7. Dis-
assembly of turbine and clutch
assembly".
3) Remove the mounting bolts, retainer (11),

and guide (12).
4. Stator assembly
Lift up and remove stator assembly (7).
a For further disassembly, see "8. Disassem-
bly of stator assembly".
4) Using push tool [7], remove bearing (13)

from guide (12).
5. Pump assembly
1) Using tool C3, remove nut (8).
HM400-2 19
6. Stator shaft 4) Using forcing screw [10], remove turbine

1) Remove the plug. Using a bar, remove (22).
inner race (15) from stator shaft (14).
a When installing the plug again, do not
apply adhesive (LT-2).
2) Remove bushing (16).
3) Remove seal ring (17).
5) Remove the mounting bolts and lift off

housing assembly (23).
6) Remove piston (24) and seal ring (25)
from the housing assembly.
7. Disassembly of turbine and clutch assem-

bly
1) Using forcing screw [8], remove input
shaft (18).
2) Using puller [9], remove bearing (19).
7) Using push tool [11], remove bearing (26)

from the housing.
9) Remove pin (28).
3) Remove snap ring (20) and plate (21).
20 HM400-2
10) Remove disc (30) from case (29). Assembly

1. Assembly of stator assembly
1) Install free wheel (36) and race (35) to
race (32).
a Install the free wheel with the arrow of
the cage end on the input side.
a Apply oil (TO30) to the sliding sur-
faces of the races.
2) Install bushings (34) and (33) to race (32).
a Install the bushings by expansion fit.
faces.
a Put in the ball without fail.
8. Disassembly of stator assembly

1) Remove the mounting bolts and stator
(31) from race (32).
3) Install stator (31) to race (32).

2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Remove bushings (33) and (34) from race a Check the rotating direction of the
(32). stator. (View from input side)
3) Remove race (35) and free wheel (36) Clockwise: Free
from race (32). Counterclockwise: Locked
HM400-2 21
2. Assembly of turbine and clutch assembly

1) Set turbine (22) and case (29) to push tool
[12].
a Use a block to prevent case (29) from
touching turbine (22).
6) Sling housing assembly (23) and install it

to case (29).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
2) Install disc (30).
faces.
7) Using push tool [13], press fit bearing (26).
3) Install pin (28).

a Install pin (28) to the housing by
expansion fit.
4) Install the seal rings (27) and (25) to pis-
ton (24) and housing (23).
2 Seal ring: Grease (G2-LI)
5) Install the piston to housing assembly
(23).
faces of the piston.
a When installing the piston take care
that the seal rings will not be caught.
22 HM400-2
8) Install plate (21) and snap ring (20). 3) Install the seal ring (17).
2 Seal ring: Grease (G2-LI)
4) Using the push tool, press fit inner race
(15).
9) Using the push tool, press fit bearing (19)

to input shaft (18).
10) Install input shaft (18) to the housing.
2 Mounting bolt: Adhesive (LT-2) 4. Pump assembly
3 Mounting bolt: 1) Using push tool [14], press fit bearing (13)
269.7 – 308.9 Nm {27.5 – 31.5 kgm} to guide (12).
3. Stator shaft 2) Set guide (12) and retainer (11) and

q The following is the assembly procedure tighten the mounting bolts.
for the torque converter. 2 Mounting bolt: Adhesive (LT-2)
1) Set stator shaft (14) to tool C1 and turn it 3 Mounting bolt:
over. 58.8 – 73.5 Nm {6 – 7.5 kgm}
2) Using the push tool, install bushing (16) by
expansion fit.
a Press fit the bushing with the chamfered end
directed to the stator shaft.
HM400-2 23
3) Set pump assembly (10) and inner race 5. Stator assembly

(9). Install stator assembly (7).
a Drop 10 cc of oil (TO30) onto the q For further assembly, see "1. Assembly of
bearing and rotate the bearing by 10 stator assembly".
turns.
6. Turbine and clutch assembly

4) Using push tool [15], press fit inner race Using eyebolt [5], set turbine and clutch
(9). assembly (6) to the pump and tighten the
mounting bolts.
3 Mounting bolt:
49.0 – 58.8 Nm {5 – 6 kgm}
5) Using tool C3, tighten nut (8).

2 Nut: Adhesive (LT-2)
3 Nut:
441.3 – 490.3 Nm {45 – 50 kgm}
24 HM400-2
7. Torque converter assembly

1) Set torque converter housing (3) to block
[3].
2) Using eyebolt [4], set torque converter
assembly (4) to torque converter housing
(3) and tighten the mounting bolts.
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
8. PTO assembly
Fit the O-ring and install PTO assembly (1),
using eyebolt [1].
HM400-2 25
Disassembly and assembly of

transmission assembly 1
Disassembly
1. Piping
Remove hoses and piping (1).
2. Wiring harness assembly

Remove wiring harness assembly (2).
3. Torque converter and transmission assem-

bly and charge pump
Remove torque converter and transmission
assembly and charge pump (3).
4. Transmission speed sensor

Remove transmission input shaft speed sensor
(4), intermediate shaft speed sensor (5)
(installed inside the cover), and rear output
shaft speed sensor (6).
a For the front output shaft speed sensor,
see "Disconnection and coupling of front
differential and transmission".
5. Torque converter oil temperature sensors

Remove torque converter oil temperature sen-
sors (7) and (8). 9. Front differential assembly
Disconnect the front differential assembly. For
6. Torque converter oil pressure sensor details, see "Disconnection and coupling of
Remove torque converter oil pressure sensor front differential and transmission".
(230).
10. Transmission control valve, main relief valve,
7. Strainer valve seat and tube.
Remove strainer (9). 1) Remove transmission control valve
assembly (12), main relief valve assembly
8. Mounting bracket and trunnion (13), valve seat (14), tube (225) and FH
Remove trunnion (10) (on the rear side) and lubrication tube (231).
mounting bracket (11) (on the front differential 2) Remove the other related tubes.
side)
26 HM400-2
11. Coupling
1) Remove rear coupling (15).
13. Covers
Remove covers (18) (on the 1st clutch side)
2) Remove input coupling (27). and (19) (on the 2nd clutch side).
a Check the thickness and quantity of the
shims on the cover (19) side.
12. Front output shaft snap ring

Remove snap ring (16).
14. Bearing cage
1) Using forcing screw [1], remove bearing
case (20).
a Check the thickness and quantity of
the shims.
HM400-2 27
2) Remove bearing outer race (38b), dust 16. Shroud

seal (67), and oil seal (68) from bearing Remove shroud (90).
cage (66).
a For bearing inner race (38a), see
"Disassembly and assembly of differ-
ential lock clutch assembly".
17. Differential lock clutch assembly

Remove differential lock clutch assembly (22).
a For further disassembly of the differential
lock clutch assembly, see "step 23".
15. Transmission case assembly (on opposite
side of torque converter)
Place the transmission with the torque con-
verter side down and remove the transmission
case assembly (21) (on the opposite side of
the torque converter).
k If the transmission is not placed with
the torque converter side down, it can-
not be disassembled. Be sure to set it
with the torque converter side down.
a If the transmission is disassembled with
the torque converter side up, its inside will
be broken. Accordingly, be sure to set it
with the torque converter side down. 18. FH and 1st clutch assembly and 2nd and
a For further disassembly of the transmis- 3rd clutch assembly
sion case, see "step 27". Lift off FH and 1st clutch assembly (23) and
2nd and 3rd clutch assembly (24) simulta-
neously.
a For further disassembly of the 2nd and 3rd
clutch assembly, see "step 24". For fur-
ther disassembly of the FH and 1st clutch
assembly, see "step 25".
28 HM400-2
19. R and FL clutch assembly 1] Remove snap ring (201), then remove
Remove R and FL clutch assembly (25). bearing and spacer and snap ring
a For further disassembly of the R and FL assembly (202).
clutch assembly, see "step 26".
2] Remove snap ring (203) from bearing

20. Cage assembly and spacer and snap ring assembly
1) Using forcing screw [2], remove cage assem- (202), then remove bearing (205)
bly (26). from spacer (204).
2) Disassemble the cage assembly accord- 3] Remove bearing outer race (38b)
ing to the following procedure. from cage (211).
HM400-2 29
21. PTO assembly 2) Disassemble the gear and shaft and ring
Remove PTO assembly (28). gear assembly according to the following
a For further disassembly of the PTO procedure.
assembly, see "step 28". 1] Using push tool [15], remove shaft
and ring gear assembly (31).
22. Torque converter assembly

Remove the bolts 12 pieces used to install the 2] Remove shaft and snap ring assem-
torque converter assembly (29) to the trans- bly (32), ring gear assembly (33), and
mission, then remove torque converter assem- bearing (34) [Inner races (34-1a), (34-
bly (29). 2a), Spacer (34-3)].
a For disassembly of the torque converter a Bearing (34) [Inner races (34-1),
assembly, see "Disassembly and assem- (34-2), (34-3)] is the assembly
bly of torque converter assembly". No.
a For bearing outer race (34-1b),
(34-2b), see 4] next page.
23. Disassembly of differential lock clutch assem-

bly
1) Using forcing screw [3], remove gear and
shaft and ring gear assembly (30).
30 HM400-2
3] Remove snap rings (36) and (68) 4) Remove snap ring (41).
from shaft (35).
a Snap ring (68) is for the oil sump.
5) Remove the mounting bolts 12 pieces and

carrier assembly (42).
4] Remove gear (37), bearing (34)
[Outer races (34-1b), (34-2b)], and
bearing inner race (38a).
6) Disassemble the carrier assembly accord-

ing to the following procedure.
1] Remove ring (43).
3) Remove snap ring (39) and sun gear (40). 2] Drive out shaft (44) toward ball (45)
and remove shaft (44), gear (46), ball
(45), bearing (47) 2 pieces, and thrust
washers (48) 2 pieces.
HM400-2 31
7) Remove front shaft and hub assembly 9) Remove end plate (55), discs (56) 7
(49). pieces, plates (57) 7 pieces, and wave
springs (58) 7 pieces from the differential
clutch.
8) Disassemble front shaft and hub assem-

bly (49) according to the following proce-
dure.
1] Remove snap ring (50), then remove
hub (52) and bearing inner race (64a)
from shaft (51).
2] Remove seal rings (53) and (54).
10) Using the hanging tap, remove piston

assembly (59).
32 HM400-2
11) Remove seal ring (61) from piston (60). 24. Disassembly of 2nd and 3rd clutch assem-
bly (2nd clutch side)
1) Remove seal rings (71) 3 pieces.
12) Disassemble the housing assembly accord-

1] Remove seal ring (63), bearing outer 2) Using puller [4], remove spacer (226) and
race (64b), and bearing inner race bearing inner race (73a) together. After
(65a) from housing (62). removing spacer (227) (2-piece type),
a For bearing outer race (65b), see remove gear (72).
"Disassembly of transmission a For bearing outer race (73b), see
case assembly on torque con- "Disassembly of transmission case
verter side". assembly on opposite side of torque
converter".
3) Remove spacer (74) (2-piece type) and

thrust washer (75).
HM400-2 33
4) Remove gear and needle roller bearing 7) Remove end plate (80), plates (81) 14
assembly (76). pieces, discs (82) 13 pieces, and wave
springs (83) 13 pieces from the 2nd clutch.
5) Remove needle roller bearing (78) from

gear (77).
8) Using the hanging tap, remove thrust wash-

ers (84) and piston assembly (86).
6) Using a C-clamp, jig [5], etc., compress
the clutch spring and remove snap ring
(79).
a The 2nd clutch has a screw hole for
eyebolt on the gear. The clutch
spring may be compressed by insert-
ing a spacer of proper thickness on
the clutch side and utilizing that screw
hole.
34 HM400-2
9) Remove seal rings (88) and (89) from pis- 12) Remove gear and needle roller bearing
ton (87). assembly (104).
(3rd clutch side) 13) Remove needle roller bearing (106) from
10) Using push puller [6], remove bearing gear (105).
inner race (100a) and spacer (101).
a For bearing outer race (100b), see
"Disassembly of transmission case
assembly on torque converter side".
14) Using C-clamp [7], etc., compress the

clutch spring and remove snap ring (107).
a The clutch spring may be com-
pressed by holding the end plate with-
11) Remove snap ring (102) and thrust washer out using the C-clamp similarly to the
(103). 2nd clutch. (For example, put a bar to
the screw hole of the shaft and press
down the end plate with the spacer.)
HM400-2 35
17) Remove seal rings (115) and (116) from

piston (114).
15) Remove end plate (108), plates (109) 8

pieces, discs (110) 7 pieces, and wave
springs (111) 7 pieces from the 3rd clutch. 25. Disassembly of 1st and FH clutch assembly
(1st clutch side)
1) Remove seal rings (121) 3 pieces.
2) Using puller [4], remove gear (122) and

bearing inner race (123a) together.
assembly on opposite side of torque
converter".
16) Remove thrust washer (112) and piston

assembly (113).
36 HM400-2
3) Remove snap ring (124) and thrust washer

(125).
4) Remove gear and needle roller bearing assem-

bly (126).

springs (133) 12 pieces from the 1st
clutch.
5) Remove needle roller bearing (128) 2 pieces
from gear (127).

a The clutch spring may be compressed
by holding the end plate without using
the C-clamp similarly to the 2nd
clutch. (For example, put a bar to the
screw hole of the shaft and press
down the end plate with the spacer.).
HM400-2 37
8) Using the hanging tap, remove thrust wash- a For bearing outer race (141b), see
ers (134) and piston assembly (136). "Disassembly of transmission case
assembly on torque converter side".

piston (137). 11) Remove needle roller bearing (145) from
gear (144).
(FH clutch side)

10) Using push puller [8], remove gear and
needle roller bearing assembly (140),
bearing inner race (141a), spacer (142),
and thrust washer (143) together.
38 HM400-2

out using the C-clamp similarly to the
2nd clutch. (For example, put a bar to
14) Using the hanging tap, remove thrust

washer (151) and piston assembly (152).

piston (153).

springs (150) 9 pieces from the FH clutch.
HM400-2 39
26. Disassembly of R and FL clutch assembly 4) Using C-clamp [11], etc., compress the
(R clutch side) clutch spring and remove snap ring (168).
1) Remove seal rings (161) 3 pieces. a The clutch spring may be com-
2) Using push puller [10], remove gear and

needle roller bearing assembly (162),
bearing inner race (163a), spacer (164),
and thrust washer (165) together.
converter".
3) Remove needle roller bearing (167) 2 pieces

from gear (166).
40 HM400-2
5) Remove end plate (169), plates (170) 12 7) Remove seal rings (176) and (177) from
pieces, discs (171) 11 pieces, and wave piston (175).
springs (172) 11 pieces from the R clutch.
(FL clutch side)

8) Using push puller [4], remove gear (178)
and bearing inner race (179a) together.

assembly (174).
9) Remove spacer (180) 2 piece type and
thrust washer (181), then remove gear
and needle roller bearing (182) assembly.
HM400-2 41
10) Remove needle roller bearings (184) 2 12) Remove end plate (186), plates (187) (12
pieces from gear (183). pieces), discs (188) 11 pieces, and wave
springs (189) 11 pieces from the FL clutch.


assembly (191).
42 HM400-2
14) Remove seal rings (193) and (194) from 28. Disassembly of transmission case assem-
piston (192). bly (on torque converter side)
Remove bearing outer races (64b), (100b),
and (141b) from the case.
27. Disassembly of transmission case assem-

bly (on opposite side of torque converter)
1) Remove holder (213), gear (214), bear- 29. Disassembly of PTO case assembly
ings (215) and (216), snap ring (217), and Disassemble the 3 idle gear according to the
collar (218). following procedure.
2) Remove bearing outer races (73b), 1) Remove nut (219) and PTO gear and
(123b), and (163b). bearing inner race assembly (220).
2) Remove bearing inner race (222a) from

PTO gear and bearing inner race assem-
bly (221).
HM400-2 43
3) Remove snap ring (223), plate (224), Assembly

bearing (222a), spacer (222b), and bear-
ing outer race (222c). q Precautions for assembly
a Clean the all parts and check them for dirt or
damage before installing.
a Coat the sliding surfaces of the all parts with
engine oil before installing.
a Dip the discs in clean oil (TO30) for at least 2
minutes before installing.
a Install seal ring (a) for the piston with the pres-
sure receiving side (side (b)) directed to hous-
ing (c) as shown in the figure.
1. Assembly of PTO case assembly

1) Install bearing outer race (222c), spacer
(222b), and bearing (222a), then fix them
with plate (224) and snap ring (223).
44 HM400-2
2) Set bearing inner race (222d) in position 2) Fit collar (218) and install bearings (215)
and install PTO gear (221) and press fit it and (216) to gear (214) by expansion fit.
by tightening nut (219). a Take care of the installing direction.
2 Bolt: Adhesive (LT-2) 3) Install snap ring (217).
3 Bolt: 4) Install gear assembly (214) by shrink fit.
313.8 – 392.3 Nm {32 – 40 kgm} a Shrink fit temperature: Approx. 120°C
for 30 minutes
5) Install holder (213) and tighten the bolts
2 Bolt: Adhesive (LT-2)
3 Bolt:
245 – 309 Nm {25 – 31.9 kgm}
2. Assembly of transmission case assembly

(on torque converter side)
Install bearing outer races (64b), (100b), and
(141b) to the case.
4. Assembly of R and FL clutch assembly

(FL clutch side)
1) Install seal rings (193) and (194) to piston
(192).
a Install the seal rings with the pressure
receiving side directed to the housing.
3. Assembly of transmission case assembly

(on opposite side of torque converter)
1) Install bearing outer races (73b), (123b),
and (163b).
HM400-2 45
2) Install piston assembly (191) and thrust 4) Install needle roller bearings (184) 2
washer (190). pieces to gear (183).
2 Apply oil (TO30) to the periphery
and contact surfaces of the seal
rings.
5) Install gear and needle roller bearing assem-

bly (182) temporarily and match the grooves
of the discs.
3) Install plates (187) 12 pieces, discs (188) a Pressing down the assembly, turn it to
11 pieces, wave springs (189) 11 pieces, the right and left and push it in gradu-
and end plate (186) to the FL clutch. ally so that it will not collide with the
a Dip the discs in clean oil (TO30) for at crests of the discs.
least 2 minutes before installing.
46 HM400-2
6) Remove the gear and needle roller bear-

ing assembly (182).
clutch spring and install snap ring (185).
9) Install gear (178), then install bearing

inner race (179a) by shrink fit.
a Shrink fit temperature: Approx. 120°C
for 30 minutes
converter".
(R clutch side)
8) Install gear and needle roller bearing assem- (175).
bly (182), thrust washer (181), and spacer a Install the seal rings with the pressure
(180) (2-piece type). receiving side directed to the housing.
a If the gear and needle roller bearing
assembly (182) is difficult to install,
repeat the procedure from step 5).
a The gear and needle roller bearing
assembly (182) may be installed first.
Then, compress the clutch spring with
C-clamp [11] and install snap ring
(180).
HM400-2 47
11) Install piston assembly (174) and thrust 13) Install needle roller bearings (167) 2
washer (173). pieces to gear (166).
2 Apply oil (TO30) to the periphery
rings.
14) Install gear and needle roller bearing assem-

bly (162) temporarily and match the grooves
of the discs.
12) Install plates (170) 12 pieces, discs (171) a Pressing down the assembly, turn it to
11 pieces, wave springs (172) 11 pieces the right and left and push it in gradu-
and end plate (169) to the R clutch. ally so that it will not collide with the
a Dip the discs in clean oil (TO30) for at crests of the discs.

ing assembly (162).
48 HM400-2
16) Using C-clamp, jig [11], etc., compress the 19) Install seal rings (161) 3 pieces.
5. Assembly of 1st and FH clutch assembly

(FH clutch side)
(153).
17) Install gear and needle roller bearing assem- 2) Install piston assembly (152) and thrust
bly (162), thrust washer (165), and spacer washer (151).
(164). a Using the hanging tap, install piston
a If gear and needle roller bearing assem-
assembly (152), taking extreme care
bly (162) is difficult to install, repeat the
procedure from step 14). that the seal rings will not be caught.
18) Install bearing inner race (163a) by shrink fit. 2 Apply oil (TO30) to the periphery
a Shrink fit temperature: Approx. 120°C and contact surfaces of the seal
for 30 minutes. rings.
"Assembly of transmission case
converter".
HM400-2 49
3) Install plates (148) 10 pieces, discs (149) 5) Install gear and needle roller bearing
9 pieces, wave springs (150) 9 pieces, assembly (140) temporarily and match the
and end plate (147) to the FH clutch. grooves of the discs.
a Dip the discs in clean oil (TO30) for at a Pressing down the assembly, turn it to
least 2 minutes before installing. the right and left and push it in gradu-
ally so that it will not collide with the
crests of the discs.

ing assembly (140).
down the end plate with the spacer.
4) Install needle roller bearing (145) to gear

(144).
50 HM400-2
8) Install gear and needle roller bearing 11) Install piston assembly (136) and thrust
assembly (140), thrust washer (143), and washer (134).
spacer (142). a Using the hanging tap, install piston
a If the gear and needle roller bearing assembly (136), taking extreme care
assembly (140) is difficult to install, that the seal rings will not be caught.
repeat the procedure from step 5). 2 Apply oil (TO30) to the periphery
rings.
9) Install bearing inner race (141a) by shrink

fit.
for 30 minutes
converter".
12) Install plates (131) 12 pieces, discs (132)

11 pieces, wave springs (133) 11 pieces,
and end plate (130) to the 1st clutch.
a Dip the discs in clean oil (TO30) for at
(1st clutch side)
(137).
HM400-2 51

ing assembly (126).
16) Using C-clamp, jig [8], etc., compress the
13) Install needle roller bearing (128) 2 pieces

to gear (127).
14) Install gear and needle roller bearing

assembly (126) temporarily and match the
grooves of the discs.
a Pressing down the assembly, turn it to
the right and left and push it in gradu-

assembly (126).
assembly is difficult to install, repeat
the procedure from step 13)
52 HM400-2
18) Install thrust washer (125) and snap ring 6. Assembly of 2nd and 3rd clutch assembly
(124). (3rd clutch side)
a Replace the snap ring with new one. 1) Install seal rings (115) and (116) to piston
a When installing the snap ring, do not (114).
expand it over 87 mm in diameter a Install the seal rings with the pressure
since the outside diameter of the receiving side directed to the housing.
spline is 85 mm.
2) Install piston assembly (113) and thrust

19) Install gear (127). washer (112).
20) Install bearing inner race (123a) by shrink 2 Apply oil (TO30) to the periphery
fit. and contact surfaces of the seal
a Shrink fit temperature: Approx. 120°C rings.
for 30 minutes
converter".
21) Install seal rings (121) 3 pieces.
HM400-2 53
3) Install plates (109) 8 pieces, discs (110) 7 5) Install gear and needle roller bearing assem-
pieces, wave springs (111) 7 pieces, and bly (104) temporarily and match the grooves
end plate (108) to the 3rd clutch. of the discs.
a Dip the discs in clean oil (TO30) for at a Pressing down the assembly, turn it to
least 2 minutes before installing. the right and left and push it in gradu-
6) Remove gear and needle roller bearing
assembly (104) again.


(105).
54 HM400-2
8) Install gear and needle roller bearing assem- 12) Install piston assembly (86) and thrust
bly (104). washer (84).
a If it is difficult to install the gear and a Using the hanging tap, install piston
needl e rol ler bearing assem bly, assembly (86), taking extreme care
repeat the procedure from 5). that the seal rings will not be caught.
9) Install thrust washer (103) and snap ring 2 Apply oil (TO30) to the periphery
(102). and contact surfaces of the seal
rings.
10) Install spacer (101), then install bearing

inner race (100a) by shrink fit.
for 30 minutes
13) Install plates (81) 14 pieces, discs (82) 13

pieces, wave springs (83) 13 pieces, and
end plate (80) to the 2nd clutch.
(2nd clutch side) a Dip the discs in clean oil (TO30) for at
(87).
HM400-2 55

ing assembly (76).
17) Using C-clamp, jig [5], etc., compress the
a The 2nd clutch has a screw hole for
eyebolt on the gear. The clutch
spring may be compressed by insert-
ing a spacer of proper thickness on
the clutch side and utilizing that screw
hole.

(77).

assembly (76) temporarily and match the
grooves of the discs.
a Pressing down the assembly, turn it to
the right and left and push it in gradu-
assembly (76).
assembly is difficult to install, repeat
the procedure from step 13).
56 HM400-2
19) Install gear (72), spacer (227) (2-piece 7. Assembly of differential clutch assembly
type), and spacer (226) (having a spline). 1) Assemble the housing assembly accord-
1] Using push tool [12], press fit bearing
inner race (65a) to housing (62).
"Disassembly of transmission
case assembly on torque con-
verter side".
20) Install bearing inner race (73a) by shrink

fit.
for 30 minutes

outer race (64b) to housing (62).
21) Install seal rings (71) 3 pieces.
3] Install seal ring (63).

a Install the seal ring with the pres-
sure receiving side directed to
the housing.
HM400-2 57
2) Install seal ring (61) to piston (60). 2] Install hub (52) to shaft (51), then
2 Apply grease (G2-LI) to the seal install snap ring (50).
ring. 3] Install seal rings (53) and (54).
a Install the seal ring with the pressure 2 Apply grease (G2-LI) to the seal
receiving side directed to the housing. rings.
3) Install piston assembly (59).

a Using the hanging tap, install piston
assembly (59), taking extreme care
that the seal rings will not be caught.
5) Install front shaft and hub assembly (49).
4) Assemble front shaft and hub assembly

(49) according to the following procedure.
inner race (64a) to shaft (51).
58 HM400-2
6) Install plates (57) 7 pieces, discs (56) 7

pieces, wave springs (58) 7 pieces, and
end plate (55) to the differential clutch.
a Dip the discs in clean oil (TO30) for at
8) Install carrier assembly (42).

3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
9) Install snap ring (41).

7) Assemble the carrier assembly according
to the following procedure.
1] Set gear (46), bearings (47) 2 pieces
and thrust washers (48) 2 pieces in
position and drive in shaft (44) half-
way and put in ball (45), then drive
shaft (44) to the end.
a First, adjust the position (direc-
tion) of the hole to put the ball in.
2] Install ring (43).
HM400-2 59
10) Install sun gear (40) and snap ring (39). 3] Using push tool [16], press fit bearing
outer race (34-2b) to gear (37).
a Bearing (34) [Inner races (34-
1a), (34-2a), (34-2b), (34-3)] is
the assembly No.
11) Assemble the gear and shaft and ring

gear assembly according to the following
procedure.
1] Install snap rings (68) and (36) to
shaft (35). 4] Install shaft and snap ring assembly
a Snap ring (68) is for the oil sump. (32) to ring gear (33).
2] Using push tool [15], press fit bearing 5] Set the snap ring side of shaft and
inner race (38a) to gear. s n ap r in g a s s em bl y ( 32 ) as th e
a For bearing outer race (38b), see receiver and press fit (install) ring
the section of bearing cage. gear (33) and bearing inner race (34-
2a) together, using push tool [17].
60 HM400-2
6] Install spacer (34-3) to shaft and ring 8. Torque converter assembly

gear assembly (69). Install torque converter assembly (29).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
a For assembly of the torque converter, see
"Disassembly and assembly of torque
converter assembly".
7] Set the snap ring side of shaft and

s n ap r in g a s s em bl y ( 32 ) as th e
receiver and press fit (install) gear
assembly (70) and bearing inner race
(34-1a) together, using push tool [18].
9. PTO assembly
Install the O-ring and PTO assembly (28).
2 O-ring on mating face: Grease (G2-LI)
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
a For assembly of the PTO assembly, see
"Assembly of PTO case assembly".
12) Install gear and shaft and ring gear

assembly (30).
10. Cage assembly

1) Assemble the cage assembly according to
1] Install bearing outer race (38b) to
cage (211).
HM400-2 61
2] Using push tool [19], press fit bearing 2) Install cage assembly (26).
(205) to spacer (204) and install snap 2 O-ring on mating face:
ring (203). Grease (G2-LI)
11. R and FL clutch assembly

Install R and FL clutch assembly (25).
a For assembly of R and FL clutch assem-
bly, see "4".
2 Apply grease (G2-LI) to the seal rings 3
places before installing transmission
case assembly (21) (on the opposite
side of the torque converter).
a Check that the seal rings (at 3 places) are
not installed with their mouths expanded.
3] Install bearing and spacer and snap

ring assembly (202), then install snap
ring (201).
62 HM400-2
12. 1st and FH clutch assembly and 2nd and 14. Shroud
3rd clutch assembly Install shroud (90).
Sling and install 1st and FH clutch assembly a Press the shroud lightly against the hous-
(23) and 2nd and 3rd clutch assembly (24) ing, then separate it from the housing by 1
simultaneously. mm and install it.
a For assembly of the 1st and FH clutch
assembly, see "5". For assembly of the
2nd and 3rd clutch assembly, see "6".
2 Apply grease (G2-LI) to the seal rings 6
places before installing transmission
case assembly (21) (on the opposite side
of the torque converter).
a Check that the seal rings (at 6 places) are
not installed with their mouths expanded.
15. Transmission case assembly (on opposite

side of torque converter)
Install transmission case assembly (21) (on the
opposite side of the torque converter).
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
a For assembly of the transmission case (on
the opposite side of the torque converter),
see "3".
13. Differential lock clutch assembly
Install differential lock clutch assembly (22).
a For assembly of the differential lock clutch
assembly, see "7".
16. Bearing cage

1) Bearing cage (2nd side)
Install outer race (129) to bearing cage
(128).
HM400-2 63
2) Bearing cage (Rear output side) 2) Install bearing cages (19) and (20) without
Using push tool [20], press fit oil seal (68) shims.
to bearing cage (66). 3 Mounting bolt:
a Dimension (f) from cage end face = 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
28.5 ± 0.2 mm 3) Rotate the output shaft 20 turns.
4) Check that the tightening torque of the
mounting bolt of bearing cage (19) and
(20) has not changed. If it has changed,
repeat steps 2) and 3).
5) Loosen the mounting bolts of bearing
cage (19) and (20) and measure the rotat-
ing torque of the output shaft.
a Rotating torque:
14.7 – 25.5 Nm {1.5 – 2.6 kgm}
6) Measure clearance (f) between bearing
cage (19) and rear transmission case at 3
places (equally spaced on the periphery)
and obtain the average.
3) Using push tool [20], press fit oil seal (67) a If the dispersion of the measured val-
to bearing cage (66). ues at the 3 places exceeds 0.15 mm,
a Dimension (g) from cage end face = check the bearing and other parts for
13.5 ± 0.2 mm abnormality. Correct any abnormal
part and measure clearance (f) again.
7) Subtract the following value from the aver-
age of clearance (f) obtained in 6) above.
Insert shims of the thickness equivalent to
the result of this calculation.
a Reduction of thickness:
0.10 – 0.15 mm
a Allowable range of shim thickness:
1.7 – 3.0 mm
8) Rotating the output shaft, tighten the
mounting bolts of bearing cage (19) to the
following torque.
3 Mounting bolt:
98 – 122 Nm {10 – 12.5 kgm}
4) Install bearing outer race (38b). 9) Measure the rotating torque of the output
shaft and check that its increase from the
value obtained in step 5) is in the following
range.
a Increase of rotating torque
2.94 – 9.81 Nm {0.3 – 1.0 kgm}
17. Procedure for installing bearing cage and

adjusting preload on tapered roller bearing
1) Engage the differential lock clutch with air.
a Keep the differential lock clutch
engaged until the following adjustment
of the shim is completed.
64 HM400-2
10) Measure clearance (a) between bearing 18. Snap ring of front output shaft
cage (20) and the rear transmission case Install snap ring (16).
at 3 places (equally spaced on the periph-
ery) and obtain the average.
a If the dispersion of the measured val-
ues at the 3 places exceeds 0.15 mm,
check the bearing and other parts for
abnormality. Correct any abnormal
part and measure clearance (a)
again.
11) Subtract the following value from the aver-
age of clearance (a) obtained in 10)
above. Insert shims of the thickness
equivalent to the result of this calculation.
a Reduction of thickness:
0.05 – 0.10 mm
a Allowable range of shim thickness:
1.50 – 3.15 mm
12) Rotating the output shaft, tighten the mount-
ing bolts of bearing cage (20) to the following
torque.
3 Mounting bolt:
98 – 122 Nm {10 – 12.5 kgm}
13) Measure the rotating torque of the output
shaft and check that its increase from the
value obtained in step 9) is in the following
range.
a Increase of rotating torque:
2.94 – 9.81 Nm {0.3 – 1.0 kgm}
19. Coupling
1) Install the O-ring, holder, and rear cou-
pling (15).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
14) Install cover (18) (1st clutch side).
HM400-2 65
2) Install input coupling (27). 21. Front differential assembly

2 Fitting part of O-ring: Couple the front differential assembly. For
Grease (G2-LI) details, see "Disconnection and coupling of
3 Mounting bolt: front differential and transmission".
245.2 – 308.9 Nm {25 – 31.5 kgm}
22. Mounting bracket and trunnion
Install mounting bracket (11) (on the front differ-
ential side) and trunnion (10) (on the rear side).
2 Mounting bolt of mounting bracket (11)
(on front differential side):
Adhesive (LT-2)
3 Mounting bolt of mounting bracket (11)
(on front differential side):
455 – 566 Nm {46.5 – 58.5 kgm}
23. Strainer
Install strainer (9).
24. Torque converter oil pressure sensor

20. Transmission control valve, torque con- Install torque converter oil pressure sensor
verter valve, valve seat and tube (230).
1) Install upper tube (225) of the transmis- 2 Threaded parts of oil pressure sensor:
sion case and FH lubrication tube (231). Gasket sealant (LG-5)

a Take care not to install the tubes in 3 Threaded parts of oil pressure sensor:
the wrong directions. 29.4 +4.9

+0 Nm {3 +0.5
+0 kgm}
2) Fit the O-rings and install valve seat (14),
transmission control valve assembly (12) 25. Torque converter oil temperature sensors
and main relief valve assembly (13). Install torque converter oil temperature sen-
3 2 mounting bolts marked with * sors (6) and (7).
(Tighten other bolts according to 2 Threaded parts: Gasket sealant (LG-5)
KES): 34 – 44 Nm {3.5 – 4.5 kgm} 3 Threaded parts:
3) Install the other related tubes. 15.7 – 19.2 Nm {1.6 – 2.0 kgm}
26. Transmission speed sensors

Install transmission input shaft speed sensor
(4), intermediate shaft speed sensor (5), and
rear output shaft speed sensor (6).
a For adjustment method and tightening
torque, see" Testing and adjusting".
a For the front output shaft speed sensor,
see "Disconnection and coupling of front
differential and transmission".
27. Torque converter and transmission charge

pump
Install the torque converter and transmission
charge pump (3).
28. Wiring harness assembly

Install wiring harness assembly (2).
66 HM400-2
29. Piping
Install pipings (1)
HM400-2 67

© 2009 KOMATSU
All Rights Reserved
68 HM400-2
SEN01445-02
HM400-2

HM400-2 2001 and up

Power train, Part 2
Disassembly and assembly of front differential assembly............................................................................... 2
Removal and installation of center differential assembly .............................................................................. 19
Disassembly and assembly of center differential assembly.......................................................................... 22
Removal and installation of rear differential assembly.................................................................................. 37
Disassembly and assembly of rear differential assembly ............................................................................. 39
HM400-2 1
Disassembly and assembly of 3. Pinion and case assembly

front differential assembly 1 1) Using forcing screw [1], remove pinion
and case assembly (9).
Special tools a Check the thickness and quantity of
the shims.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-201-2850 Spacer t 1
1 790-201-2740 Spacer t 1
790-201-2750 Spacer t 1
790-101-5481 • Plate 1
2
790-101-5421 • Grip 1
H
01010-51240 • Bolt 1
790-201-2770 Spacer t 1
3
792T-423-1130 Push tool t 1 N Q
790-201-2740 Spacer t 1
4 792T-423-1110 Push tool t 1 N Q
792T-423-1120 Push tool t 1 N Q
Disassembly
1. Speed sensor and top cover
Remove speed sensor (1) and top cover (2).
2) Disassemble pinion and case assembly

(9) according to the following procedure.
1] Remove case assembly (10) from
pinion assembly (11).
2. Bevel gear supporting bolt

Remove bevel gear supporting bolt (4).
2 HM400-2
4. Input shaft coupling and holder

Remove holder (5) and coupling and gear
assembly (6).
2] Remove spacer (12) and bearing

inner race (13a).
5. Right and left output shaft couplings

Remove couplings (17) and (18) on both sides.
a Check the thickness and quantity of the
shims.
3] Remove seals (14) and (15), bearing

(16), and bearing outer race (13b)
from case (11).
6. Side carrier and shaft assembly

1) Sling the differential gear case with wires
and remove side carrier and shaft assem-
bly (19) on the bevel gear side by using
forcing screw [1].
the shims.
HM400-2 3
2) Under the above condition, remove side

carrier and shaft assembly (20) on the
opposite side by using forcing screw [2].
the shims and the position of the side
carrier.
2) Disassemble the differential gear and dif-

ferential lock assembly according to the
1] Using pullers [3] (98 kN {10 ton}) and
[4], remove retainer (23) and bearing
inner race (24a).
a For disassembly of side carrier and

shaft assembly, see "8".
7. Differential gear and differential lock

assembly
1) Remove the mounting bolts (21) 3 pieces
from the retainer of the differential gear
case, then remove differential gear and dif-
ferential lock assembly (22).
4 HM400-2
4] Remove piston (28) from case (27).

a Piston (28) may be left below (on
the differential case side). In that
case, remove the piston sepa-
rately.
2] Remove seal ring (25).
5] Remove seal ring (29) from piston

(28).
a Check the direction of the seal
ring.
3] Remove case and piston assembly

(26).
6] Remove seal ring (30) and thrust

washer (68) from case (27).
HM400-2 5
7] Remove plate (31), disc (32), and pin

(33).
9] Remove washer (41) and differential

side gear (42).
8] Bevel gear assembly
1> Turn over the assembly and
remove mounting bolts (36) 12
pieces of bevel gear assembly
(35) of case (34), then remove
bevel gear assembly (35).
a Check the match marks on the
b ev el ge ar an d c as e b efo r e
removing the bevel gear assem-
bly (on the tooth surface side of
the bevel gear).
2> Using puller [5], remove bearing

inner race (38a) from bevel gear
and case assembly (37). 10] Remove pinion gear assembly (43)
3> Remove case (39) from bevel and cross shaft (44) in 1 unit.
gear (40).
6 HM400-2
11] Remove washer (45), pinion gear 8. Disassembly of side carrier and shaft
(46), and bushing (sleeve) (47). assembly
1) Disassemble the side carrier and shaft
assembly on the bevel gear side accord-
1] Remove seal (49).
12] Remove side gear (48).
2] Shaft and bearing inner race assem-

bly
1> Remove shaft and bearing inner
race assembly (50)
2> Using push tool [6], remove bear-

ing inner race (51a).
HM400-2 7
3] Remove bearing (53) and bearing 2> Using push tool [7], remove bear-
outer races (38b) and (51b) from case ing inner race (56a).
(52).
a Bearing (53) is divided into the
inner race and outer race when
the shaft is removed (pulled out).
3) Remove bearing (58) and bearing

outer races (24b) and (56b) from case
(57).
a Bearing (58) is divided into the
2) Disassemble the side carrier and shaft inner race and outer race when
assembly on the opposite side of the the shaft is removed (pulled out).
bevel gear according to the following pro-
cedure.
1] Remove seal (54).

bly
1> Remove shaft and bearing inner
race assembly (55).
8 HM400-2
Assembly
a If a tool for installing a seal is not specified (for
the input shaft in particular), use a push tool of
a proper size for each part.
1. Assembly of side carrier and shaft assem-
bly
1) Assemble the side carrier and shaft
assembly on the bevel gear side accord-
1] Install bearing outer races (38b),
(51b), and (53b) to case (52).
3> Adjust the shims for the bearing

according to the following proce-
dure.
a) Measure the starting tangential
force in the tangential direction of
the bolt hole (ø234) of the case.
a Standard tangential force:
Max. 21.5 N {2.2 kg}
b) If the starting tangential force is
too large, increase the shims. If
the former is too little, decrease
the latter. Then, measure the
2] Shaft and bearing inner race assem- starting tangential force again.
bly a If the starting tangential force
1> Using tool H4, press fit bearing is tool large, disassemble
inner race (51a) to shaft (59). shaft and bearing inner race
as sem bly ( 50) an d c as e
assembly (61) and increase
the shims, then execute 2]
above.
2> Set the standard shims (having

the thickness and quantity
checked when disassembled)
and install coupling (17). Using
push tool [7], press holder (60) to
press fit case assembly (61) to
shaft and bearing inner race
assembly (50).
HM400-2 9
3] Using tool H3, press fit seal (49). 2> Set the standard shims (having
the thickness and quantity
checked when disassembled)
and install coupling (18). Using
push tool [7], press holder (65) to
press fit case assembly (66) to
shaft and bearing inner race
assembly (55).
2) Assemble the side carrier and shaft

assembly on the opposite side of the
bevel gear according to the following pro-
cedure.
1] Install bearing outer races (24b),
(56b), and (58b) to case (57).
3> Adjust the shims for the bearing

according to the following proce-
dure, similarly to the side carrier
on the bevel gear side.
a) Measure the starting tangential
force in the tangential direction of
the bolt hole (ø208) of the case.
a Standard tangential force:
Max. 24.5 N {2.5 kg}
b) If the starting tangential force is
too large, increase the shims. If
the former is too little, decrease
the latter. Then, measure the
starting tangential force again.
bly
a If the starting tangential
1> Using tool H4, press fit bearing
force is tool large, disassem-
inner race (56a) to shaft (63).
ble shaft and bearing inner
race assembly (55) and
cas e ass embl y ( 65) a nd
increase the shims, then
execute 2] above.
3] Using tool H3, press fit seal (54).
10 HM400-2
a The procedure for installing both side carrier 3] Install pinion gear assembly (43) and
and shaft assemblies to the body is explained cross shaft (44) in 1 unit.
in 3 below.
2. Differential gear and differential lock assem-

bly
1) Assemble the differential gear and differ-
ential lock assembly according to the fol-
lowing procedure.
1] Install side gear (48).
4] Install differential side gear (42) and

washer (41).
2] Install bushing (sleeve) (47), pinion

gear (46), and washer (45).
HM400-2 11
5] Bevel gear assembly 7] Install seal ring (30) and thrust

1> Install case (39) to bevel gear washer (68) to piston case (27).
(40). a When installing the seal ring,
2 Mounting bolt: take care of its direction.
Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
2> Install bearing inner race (38a) to
bevel gear and case assembly
(37) by shrink fit.
a Shrink fit temperature:
120°C for 30 minutes
8] Install seal ring (29) to piston (28).

a When installing the seal ring,
take care of its direction.
3> Install bevel gear assembly (35)

to case (34).
a Match the match marks to each
other.
9] Install piston (28) to case (27).
6] Install pin (33), plate (31), and disc

(32).
a Apply engine oil (EO-30) to the
surfaces of the disc and plate.
10] Install case and piston assembly (26).

3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
12 HM400-2
2) Sling differential gear and differential lock

assembly (22) and install it to differential
gear case (67) and tighten the retainer
mounting bolts (21) 3 pieces.
11] Install seal ring (25).

a When installing the seal ring,
take care of its direction.

inner race (24a) and retainer (23) in 1 3. Side carrier and shaft assembly
unit. 1) Sling the differential gear case and set the
standard shims (having the thickness and
quantity checked when disassembled)
and install side carrier and shaft assembly
(19) on the bevel gear side.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
HM400-2 13
2) Under the above condition, set the stan- 4. Right and left output shaft couplings
dard shim (having the thickness and quan- Install couplings (17) and (18) on both sides.
tity checked when disassembled) and 2 Mounting bolt: Adhesive (LT-2)
install side carrier and shaft assembly (20) 3 Mounting bolt:
on the opposite side. 490 – 608 Nm {50 – 62 kgm}
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
5. Pinion and case assembly

1) Assemble pinion and case assembly (9)
3) Adjusting preload on side bearing according to the following procedure.
1] Measure the initial rotating force of 1] Using push tool [10], install bearing
the periphery of the bevel gear in the outer race (13b) to case (11).
tangential direction. 2] Using push tool [11], install bearing
a Initial rotating force: outer race (16b) to case (11).
6.86 – 25.0 N {0.7 – 2.55 kg}
2] If the rotating force is larger than the
standard level, increase the thick-
ness/quantity of the shims. If the
former is in the standard range, it is
normal.
a After adjusting the tooth contact
and backlash, the shims on both
sides may be exchanged with
each other. Do not change the
total quantity and thickness of
the shims on both sides, how-
ever.
4) After adjusting the preload, be sure to
3] Using tool H1, press fit bearing inner
tighten the mounting bolts to the specified
race (13a) to pinion (10).
torque in 1).
4] Install spacer (12).
14 HM400-2
2) Using tool H1, press fit case assembly

(11) to pinion (10).
a Never push the case assembly with a
press.
a Press fit bearing inner race (16a) with
tool H1.
a Press fitting force:
0 – 8,134 N {0 – 830 kg}
a Press fit case assembly (11), turning
it.
3) Set the standard shim (having the thick-

ness and quantity checked when disas-
sembled) and install pinion and case
assembly (9).
a Tighten 3 mounting bolts first.
a After adjusting the tooth contact,
tighten the all mounting bolts.
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
6. Input shaft coupling and holder

1] Using push tool [12], press fit 1) Using push tool [13], press fit speed
seal (15) to case (11). detection gear (8) to coupling (7).
2 Apply Sealend 242 to the periph- a Press fit the gear until it is flush with
ery of the seal. the coupling.
a Taking care of the direction of the
seal, press fit it until it is flush
with the case as shown in the fig-
ure.
a Press fit the seal so that standard
dimension (a) will be 110 mm.
2] Using tool H2, press fit seal (14)
to case (11).
2 Apply Sealend 242 to the periph-
ery of the seal.
a Taking care of the direction of the
seal, press fit it until it is flush
with the case as shown in the fig-
ure.
HM400-2 15
2) Install coupling and gear assembly (6) and

holder (5).
2 Holder end (Face to be in contact
with bearing at bottom):
Adhesive (LMP)
Adhesive (LT-2)
824 – 1,030 Nm {84 – 105 kgm}
2) Adjust the tooth contact according to the

1] Adjust the projection of the bevel pin-
ion with shim (71) between the differ-
ential case and bearing case.
7. Adjusting tooth contact and backlash

q Adjust the backlash and tooth contact
simultaneously.
1) Adjust the backlash according to the fol-
lowing procedure.
1] Move the bevel gear by increasing or
decreasing shims (69) and (70) of the
right and left carrier assemblies. At
this time, do not change the total
quantity and thickness of the shims
on both sides so that the preload on q When the backlash is below standard
the bearing will not change. value
Loosen the adjustment nut on the bevel
gear side and tighten the adjustment nut
on the right side by the same angle (to
move the bevel gear in the direction of A).
q When the backlash is above standard

value
Loosen the adjustment nut on the left side
and tighten the adjustment nut on the
bevel gear side by the same angle (to
move the bevel gear in the direction of B).
2] Apply dial gauge [13] perpendic-

ularly to the reversing tooth sur-
face at the outer end of the bevel
gear. Adjust the backlash so that
the gauge will indicate 0.3 –
0.4mm.
a Adjust the backlash at 3 – 4
places and measure it with the
pinion fixed.
16 HM400-2
(1) Checking tooth contact q In this case, adjust the tooth contact
Apply red lead thinly to the surfaces of 7 - according the following procedure
8 teeth of the bevel gear and turn the
bevel gear in the forward and reverse If bevel pinion is too far from bevel gear
directions, then check the tooth contact a The tooth contact pattern is as fol-
pattern on the bevel gear. lows.
a The center of the tooth contact must q Decrease the shims of the bevel pin-
be as follows. ion to move the bevel pinion in direc-
q Middle of tooth height tion (C).
q Point on tooth at distance of (x) from q Move the bevel gear in direction (D).
small end (C)
(Approx. 33% of tooth length)
a Width (y) of the tooth contact must be
30 - 60% of the tooth length.
a Check that there is not a strong con-
tact at tip (A), bottom (B), small end
(C) or large end (D).
If bevel pinion is too close to bevel gear

a The tooth contact pattern is as fol-
lows.
q Increase the shims of the bevel pinion
to move the bevel pinion in direction
(E).
q Move the bevel gear in direction (F).
(2) Adjusting tooth contact

If the tooth contact pattern is not proper,
adjust the tooth contact according to the
procedure shown in the following page.
check the backlash again.
HM400-2 17
If bevel gear is too close to bevel pinion 8. Bevel gear supporting bolt
a The tooth contact pattern is as fol- Install bevel gear supporting bolt (4).
lows. a Bring the bolt end in contact with the back
q Decrease the shims of the bevel pin- of the gear, then return it by 3/4 turn and
ion to move the bevel pinion in direc-
tion (C). secure it with the locknut.
q Move the bevel gear in direction (D). 2 Bolt: Gasket sealant (LG-5)
3 Locknut: 196 – 245 Nm {20 – 25kgm}
If bevel gear is too far from bevel pinion

a The tooth contact pattern is as fol- 9. Speed sensor and top cover
lows. Install speed sensor (1) and top cover (2).
2 Top cover: Gasket sealant (LT-515)
3 Top cover mounting bolt:
(E).
q Move the bevel gear in direction (F). 157 – 196 Nm {16 – 20 kgm}
a After adjusting the tooth contact, refer

to the following sections and observe
the application of adhesive and tight-
ening torque.
q Mounting bolts of right and left bevel
gear side carriers
q Right and left output shaft couplings
q Pinion and case assembly
q Input shaft
18 HM400-2
Removal and installation of center 4. Drive shaft between center differential and
differential assembly 1 rear differential
Remove the guard and disconnect the center
Removal differential end of drive shaft (3) between then
center differential and rear differential. [*2]
k Raise the dump body and insert the lock
pin.
1. Draining oil
Drain oil from the center differential case and
center final drive case.
2. Sun gear and drive shaft

Remove the center final drive cover and pull
out sun gear and drive shaft (1) (from both
sides).
5. Coupling on rear differential side

Remove the holder, coupling (4) on the rear
differential side, and cover (5). [*3]
3. Drive shaft between hitch frame and center

differential
Remove the guard and lift and disconnect the
center differential end of drive shaft (2)
between the hitch frame and center differential. 6. Rear differential drive shaft and bearing
[*1] cage assembly
Using forcing screw [1], remove rear differen-
4 Drive shaft between hitch frame and tial drive shaft (6) and bearing cage assembly
center differential (Only center differen- (7) in 1 unit.
tial end): 35 kg
a Make match marks so that the spline will
not shift in the circumferential direction.
HM400-2 19
7. Piping and wiring harness Installation

Disconnect differential lock hoses (8) – (10), q Carry out installation in the reverse order to
brake hose (11), brake cooling hoses (12) 3 removal.
pieces, and rear retarder oil temperature sen-
sor connector (CN-T14) (13), then remove [*1]
brake cooling tube (14). a When installing the drive shaft, check that the
2 Mounting bolt of drive shaft between hitch
frame and center differential:
Adhesive (LT-2)
frame and center differential:
157 – 198 Nm {16 – 20 kgm}
[Target: 177 Nm {18 kgm}]
[*2]
a When installing the drive shaft, check that the
8. Center differential assembly the mating yoke and tighten the bolts.
2 Mounting bolt of drive shaft between center
Sling center differential (15) temporarily. Using
forcing screws (M14 x 2), pull out the center differential and rear differential:
differential. After pulling out the differential Adhesive (LT-2)
halfway, change the slinging position (increase
the number of slings) and remove the differen- differential and rear differential:
tial. [*4] 98 – 123 Nm {10 – 12.5 kgm}
4 Center differential assembly: 380 kg
[*3]
a When installing a seal to a cover, use a push
tool matched to the diameter of that seal.
2 Seal lip: Grease (G2-LI)
3 Cover mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
a Install the rear (output) coupling so that the

phase difference between it and the front
(input) coupling will be 6° or less.
2 Coupling holder mounting bolt:
Adhesive (LT-2)
3 Coupling holder mounting bolt:
490 – 608 Nm {50 – 62 kgm}
[*4]
3 Center differential mounting bolt:
157 – 198 Nm {16 – 20 kgm}
k After installing, bleed air from the brake cir-

cuit. For details, see "Testing and adjusting,
Bleeding air from brake circuit".
20 HM400-2
Refilling with oil

q Pour the specified oil in the center differential
case and final drive case to the specified level.
q Check the oil level in the transmission case
and add the specified oil to the specified level if
necessary.
q Check the oil level in the hydraulic tank and
add the specified oil to the specified level if
necessary.
HM400-2 21
Disassembly and assembly of 2. Cover

center differential assembly 1 Remove cover (1).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
5 792T-423-1130 Push tool t 1 N Q
792-103-0901 Wrench t 1
6 792-222-1110 Adapter t 2
796-751-1500 Wrench assembly t 1
7 3. Transfer input coupling and holder
795-630-1803 Torque wrench t 1
Remove holder (2) and coupling (3).
8 792T-422-1250 Push tool t 1 N Q
H 9
790-901-2110 Bracket t 1
793-310-2141 Plate t 1 R Q
792T-423-1140 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
11 790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1 4. Cage
1) Using forcing screw [1], remove cage
Disassembly assembly (4).
1. Set the center differential gear assembly to tool the shims.
H9.
22 HM400-2
2) Remove side seal (5), oil seal (6), and 6. Input shaft holder
bearing outer race (7b) from cage (12). a Place a wood block, etc. so that the bevel
pinion will not fall.
1) Remove holder (13).
the shims.
5. Transfer input shaft and gear assembly

1) Remove transfer input shaft and gear
assembly (8).
2) Remove holder (14) and key (15).
2) Disassemble transfer input shaft and gear

assembly (8) according to the following
procedure.
q Remove bearing inner race (7a),
spacer (11), and gear (12) from trans-
fer input shaft (9).
HM400-2 23
7. Transfer case 8. Input gear and spacer

1) Using forcing screw [2], remove transfer Remove spacer (19) and input gear (20).
case assembly (16). a Check the identification mark (A – J) of the
spacer.
9. Cage assembly
1) Using forcing screw [3], remove cage
assembly (21).
the shims.
2) Remove bearing outer race (10b) and

bearing (18) from transfer case (17).
2) Remove bearing outer race (23b) from

cage (22).
24 HM400-2
10. Pinion assembly

1) Remove pinion assembly (24).
5) Disassemble the differential gear case

assembly according to the following pro-
2) Disassemble pinion assembly according to cedure.
the following procedure. 1] Gear case
Remove bearing inner race (21a) from pin- 1> Set the gear case to a block
ion (25).
(Height: Approx. 200 mm).
2> Remove mounting bolts (33) 20
pieces.
3> Lift off case (34) with wires.
4> Remove seal rings (35) and (36)
from case (34).
2] Remove washer (37) and pin (38).
3] Remove piston (39).
q Remove seal ring (40) from pis-
ton (39).
4] Using a bearing puller, remove bear-
5] Remove sleeve (42).

bly
a Sling the differential case in advance.
1) Remove locks (26) and (27).
2) Using tool H6, loosen adjustment nuts
(28) and (29) to the degree that you can
turn them with fingers.
3) Loosen bolts (30) 4 pieces.
4) Using wires, sling the differential gear
case assembly. Remove bearing caps
(31) and (32), nuts (28) and (29) and dif-
ferential gear case assembly.
a Take care not to drop the bearing
outer race.
HM400-2 25
6] Remove plate (43) and disc (44).

7] Remove pins (45) 4 pieces.
9] Remove washer (53) and differential

side gear (54).
a Check the match marks on the
b ev el ge ar an d c as e b efo r e
removing the bevel gear assem-
bly (on the tooth surface side of
the bevel gear).

and case assembly (49). 10] Remove pinion gear assembly (55)
3> Remove case (51) from bevel and cross shaft (56) in 1 unit.
gear (52).
26 HM400-2
11] Remove washer (57), pinion gear Assembly

(58), and bushing (sleeve) (59).

bly
lowing procedure.

HM400-2 27
3] Install pinion gear assembly (55) and 5] Bevel gear assembly

cross shaft (56) in 1 unit. 1> Install case (51) to bevel gear
(52).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
2> Install bearing inner race (50a) to
bevel gear and case assembly
(49) by shrink fit.

washer (53).

to case (46).
a Match the match marks to each
other.
28 HM400-2
6] Turn over the case and install pin 2. Assembly of differential

(45), disc (44), and plate (43). 1) Differential gear assembly
a Apply engine oil (EO-30) to the 1] Install nuts (28) and (29), matching
surfaces of the disc and plate. them to the grooves of differential
case (61).
2] Sling gear case (62) and install the
outer race to the bearing, then install
them to differential case (61).
7] Install seal ring (40) to piston (39).

a Take care of the direction of the
seal ring.
8] Install seal rings (35) to case (34).
seal rings. 3. Caps
9] Install pin (38) and washer (37). 1) Install caps (31) and (32) and tighten bolt
10] Install piston (39) to case (34). (30) temporarily.
11] Install the case and piston assembly, 2) Using tools [5] and [6], tighten bolt (30).
3 Bolt:
matching it to the position of pin (45).
3 Case mounting bolt:
824 – 1,040 Nm {84 – 105 kgm}
157 – 196 Nm {16 – 20 kgm}
12] Install seal ring (36) to case (34).
seal rings.
13] Install sleeve (42), taking care not to
damage seal ring (36).
14] Install bearing (41a) to case (34) by
shrink fit.
HM400-2 29
4. Adjusting preload on bearing 5. Assembly of transfer input shaft

1) Rotate the adjustment rings (28) and (29) Assemble transfer input shaft assembly (8)
with bar H6 until the ring gear reaches the according to the following procedure.
pinion gear and the backlash is elimi- q Install gear (12) and spacer (11) to trans-
nated. fer input shaft (9). Using push tools [7]
a Rotate the bearing sufficiently so that and [8], press fit bearing inner race (7a).
it will come in contact with the other
contact surfaces and hit the ring gear
with a copper hammer, etc.
a Apply sufficient amount of oil to the
bearing.
a If you loosened either adjustment ring
by 1 turn, tighten the other one by 1
turn.
2) Install a spring balance to the ring gear
and measure the free rotating force at this
time.
Starting tangential force:
10.1 – 19.4 N {1.03 – 1.98 kg}
6. Assembly of cage of transfer input shaft
1) Assemble cage assembly (4) according to
1] Install bearing outer race (7b).
2] Using push tool [9], install oil seal (6).
3] Using push tool [10], install side seal

(5).
30 HM400-2
7. Assembly of transfer case 9. Assembly of bevel pinion assembly

Install bearing outer race (10b) and bearing Assemble bevel pinion assembly according to
outer race (18b) to transfer case (17). the following procedure.
q Using push tool [12], press fit bearing
inner race (21a) to pinion (25).
8. Adjusting preload on bearing of transfer

input shaft
1) Install input shaft and gear assembly (8) to
transfer case (17) without inserting any 10. Adjustment of preload on bevel pinion sup-
shim. Install cage assembly (12) and port bearing
tighten mounting bolts (64) 8 pieces to 113.0 1) Install pinion assembly (24).
Nm {11.5 kgm}.
a At this time, tighten mounting bolts
(64) repeatedly, rotating the bearing,
until rotation is stabilized.
2) Sling the coupling with a crane and mea-
sure the end play after adjustment with
dial gauge [11]. Determine the thickness
of the shims (a) so that end play will be 0 –
0.05 mm.
3) After checking the thickness of the shims,
remove input shaft and gear assembly (8)
and cage assembly (12).
2) Cage assembly
1] Install bearing outer race (23b) to
cage (22).
HM400-2 31
2] Install cage assembly (21).
5) Bearing inner race

3) Input gear and spacer Using push tool [13], press fit bearing
Install input gear (20) and spacer (19). inner race (18a).
a Install the spacer checked when dis-
assembled.
MD shim Part No. Letter stamped
Spacer width
thickness range of spacer on spacer
0.013 - 0.113 56B-23-16910 A 25.887±0.025
0.114 - 0.213 56B-23-16920 B 25.787±0.025
0.214 - 0.313 56B-23-16930 C 25.687±0.025
0.314 - 0.413 56B-23-16940 D 25.587±0.025
0.414 - 0.513 56B-23-16950 E 25.487±0.025
0.514 - 0.613 56B-23-16960 F 25.387±0.025
0.614 - 0.713 56B-23-16970 G 25.287±0.025
0.714 - 0.813 56B-23-16980 H 25.187±0.025
0.814 - 0.913 56B-23-16990 J 25.087±0.025
4) Transfer case 6) Input shaft holder

Install transfer case assembly (16). 1] Install holder (14) and key (15).
a Check that the bearing of the pinion is
fitted accurately.
32 HM400-2
2] Set the standard shim (having the

thickness and quantity checked when
disassembled) and install holder (13).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
a Execute "11. Adjusting tooth con-
tact and backlash", then deter-
mine the quantity and thickness
of the shims.
2] Apply dial gauge [11] perpendicularly

to the reversing tooth surface at the
outer end of the bevel gear. Rotate
the adjustment nuts until the dial
gauge indicates 0.3 – 0.4mm.
places and measure it with the
pinion fixed.
7) Measurement of turning torque

Measure the starting tangential force
(torque) of the input shaft with push-pull
scale [14] and check that the result is as
follows.
a Starting tangential force (torque)
Starting torque:514.8 – 1,543.5 Nm
{52.5 – 157.5 kgm}
(Measure this torque by putting a
wrench to the shaft end bolt.)
2) Adjust the tooth contact according to the

1] Adjust the projection of the bevel pin-
ion with shim (65) between differential
case (64) and transfer case (17).
2] Adjusting tooth contact
a See "Adjusting tooth contact" in
3) below
11. Adjusting tooth contact and backlash

Adjust the backlash and tooth contact simulta-
neously.
1) Adjust the backlash according to the fol-
lowing procedure.
1] Move the bevel gear with adjustment
nuts (28) and (29). At this time, turn
the nuts on both sides by the same
angle in the same direction so that
the preload on the bearing will not
change.
HM400-2 33
3) Adjusting tooth contact of bevel gear and (2) Adjusting tooth contact
bevel pinion If the tooth contact pattern is not proper,
q When the backlash is below standard adjust the tooth contact according to the
value procedure shown in the following page.
Loosen the adjustment nut on the bevel a After adjusting the tooth contact,
gear side and tighten the adjustment nut check the backlash again.
on the right side by the same angle (to
move the bevel gear in the direction of A). If bevel pinion is too far from bevel gear
q When the backlash is above standard lows.
value q Decrease the shims of the bevel pin-
Loosen the adjustment nut on the left side ion to move the bevel pinion in direc-
and tighten the adjustment nut on the tion (C).
bevel gear side by the same angle (to q Move the bevel gear in direction (D).
If bevel pinion is too close to bevel gear

(1) Checking tooth contact a The tooth contact pattern is as fol-
Apply red lead thinly to the surfaces of 7 – lows.
8 teeth of the bevel gear and turn the q Increase the shims of the bevel pinion
bevel gear in the forward and reverse to move the bevel pinion in direction
directions, then check the tooth contact (E).
pattern on the bevel gear. q Move the bevel gear in direction (F).
a The center of the tooth contact must
be as follows.
q Middle of tooth height
q Point on tooth at distance of (x) from
small end (C)
30 – 60% of the tooth length.
34 HM400-2
If bevel gear is too close to bevel pinion 13. Cage

a The tooth contact pattern is as fol- 1) Install bearing outer race (7b) to cage
lows. (10). Using tool H11, press fit oil seal (6).
q Decrease the shims of the bevel pin- a Press fit oil seal (6) so that clearance
ion to move the bevel pinion in direc- (c) between the periphery of oil seal
tion (C). (6) and cage (10) will be 10 ± 0.5 mm.
q Move the bevel gear in direction (D).
2) Using tool H5, press fit side seal (5) to

If bevel gear is too far from bevel pinion cage (10).
a The tooth contact pattern is as fol- a If the side seal is press fitted with this
lows. tool until it is flush with the cage, it is
q Increase the shims of the bevel pinion positioned accurately.
(E).
3) Set the standard shims and install cage

assembly (4).
12. Transfer input shaft and gear assembly

Install transfer input shaft and gear assembly
(8).
HM400-2 35
14. Transfer input coupling and holder 16. Bevel gear supporting bolt
Install coupling (3) and holder (2). Install bevel gear supporting bolt (66).
2 End of bearing (Part A): a Bring the bolt end in contact with the back
Grease (G2-LI) of the gear, then return it by a half turn and
2 End of side seal (Part B): secure it with the locknut.
Grease (G2-LI) 2 Bolt: Gasket sealant (LG-5)
2 Holder mounting bolt: Adhesive (LT-2) 3 Locknut:
3 Holder mounting bolt: 196 – 245 Nm {20 – 25kgm}
824 – 1,030 Nm {84 – 105 kgm}
a For disassembly and assembly of the out-

put section of the center axle transfer, see
"Removal and installation of center differ-
ential assembly".
15. Cover
Install cover (1).
36 HM400-2
Removal and installation of rear 4. Piping and wiring harness

differential assembly 1 Disconnect differential lock hoses (3) – (5),
brake hose (6), brake cooling hoses (7) 3
Removal pieces, and rear brake oil temperature sensor
connector (CN-T13) (8), then remove brake
k Disconnect the cable from the negative (–) cooling tube (9).
pin.
1. Draining oil
Drain oil from the rear differential case and
rear final drive case.

Remove the rear final drive cover and pull out
sun gear and drive shaft (1) (from both sides).
5. Rear differential assembly

Sling rear differential (10) temporarily. Using
forcing screws (M14 x 2), pull out the rear dif-
ferential. After pulling out the differential half-
way, change the slinging position (increase the
number of slings) and remove the differential.
[*2]
a Support the rear differential from its under-
side, too, with transmission jack [1], etc.
a Since the rear side of the rear differential
is a little low, it does not come out easily.
Accordingly, use guide bolt [2], etc. to pull
3. Drive shaft between center differential and out the rear differential forward carefully.
rear differential 4 Rear differential assembly: 280 kg
differential end of drive shaft (2) between then
center differential and rear differential. [*1]
HM400-2 37
Installation
removal.
[*1]
differential and rear differential:
Adhesive (LT-2)
98 – 123 Nm {10 – 12.5 kgm}
[*2]
2 Rear differential mounting bolt:
157 – 198 Nm {16 – 20 kgm}

cuit. For details, see "Testing and adjust-
ing, Bleeding air from brake circuit".
Refilling with oil

q Pour the specified oil in the rear differential
case and rear final drive case to the specified
level.
necessary.
necessary.
38 HM400-2
Disassembly and assembly of 3. Pinion and cage assembly

rear differential assembly 1 1) Using forcing screw [1], remove pinion
and cage assembly (3).
Special tools a Check the thickness and quantity of
the shims.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
5 792T-423-1130 Push tool t 1 N Q
792-103-0901 Wrench t 1
6 792-222-1110 Adapter t 2
9
790-901-2110 Bracket t 1
H 793-310-2141 Plate t 1 R Q
792T-423-1140 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
11 790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Disassembly
1. Set the rear differential gear assembly to tool 2) Remove side seal (6) and oil seal (7) from
H9. pinion and cage assembly (5).
2. Input coupling and holder

Remove holder (1) and coupling (2).
HM400-2 39
3) Remove pinion assembly (8) from cage 4. Differential gear and differential lock assem-
assembly (9). bly
a Sling the differential case in advance.
1) Remove locks (26) and (27).
2) Using tool H6, loosen adjustment nuts
(28) and (29) to the degree that you can
turn them with fingers.
3) Loosen bolts (30) 4 pieces.
4) Sling the differential gear case assembly
with wires and remove bearing caps (31)
and (32) and nuts (28) and (29), then
remove the differential gear case assem-
bly.
a Take care not to drop the bearing
outer race.
4) Disassembly of pinion assembly
Remove spacer (11) and bearing inner
race (12a) from pinion (10).
5) Disassembly of cage assembly

Remove bearing (14) and bearing outer
race (12b) from cage (13).
a The inner race of bearing (14) was
removed in 3) above.
5) Disassemble the differential gear case

assembly according to the following pro-
cedure.
1] Gear case
1> Set the gear case to a block
(Height: Approx. 200 mm).
2> Remove mounting bolts (33) 20
pieces.
3> Lift off case (34) with wires.
from case (34).
2] Remove washer (37) and pin (38).
3] Remove piston (39).
q Remove seal ring (40) from pis-
ton (39).
40 HM400-2
4] Using a bearing puller, remove bear-

5] Remove sleeve (42).

and case assembly (49).
3> Remove case (51) from bevel
gear (52).
6] Remove plate (43) and disc (44).

7] Remove pins (45) 4 pieces.

a Check the match marks on
the bevel gear and case
before removing the bevel
gear assembly (on the tooth
surface side of the bevel
gear).
HM400-2 41
9] Remove washer (53) and differ- 11] Remove washer (57), pinion gear
ential side gear (54). (58), and bushing (sleeve) (59).
10] Remove pinion gear assembly

(55) and cross shaft (56) in 1
unit.
42 HM400-2
Assembly 3] Install pinion gear assembly (55) and

a If a tool for installing a seal is not specified (for cross shaft (56) in 1 unit.

bly
lowing procedure.

washer (53).


1> Install case (51) to bevel gear
(52).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
HM400-2 43
2> Install bearing inner race (50a) to 7] Install seal ring (40) to piston
bevel gear and case assembly (39).
(49) by shrink fit. a Take care of the direction of
a Shrink fit temperature: 120°C the seal ring.
for 30 minutes 8] Install seal rings (35) to case
(34).
a Take care of the direction of
the seal rings.
9] Install pin (38) and washer (37).
10] Install piston (39) to case (34).
11] Install the case and piston assem-
bly, matching it to the position of
pin (45).
3 Case mounting bolt:
157 – 196 Nm {16 – 20 kgm}
12] Install seal ring (36) to case (34).
a Take care of the direction of
the seal rings.
13] Install sleeve (42), taking care
not to damage seal ring (36).
to case (46).
14] Install bearing (41a) to case (34)
a Match the match marks to
by shrink fit.
each other.
a Shrink fit temperature: 120°C
for 30 minutes
6] Turn over the case and install pin

(45), disc (44), and plate (43).
a Apply engine oil (EO-30) to the
surfaces of the disc and plate.
44 HM400-2
2. Assembly of differential 2) Install a spring balance to the ring gear

1) Differential gear assembly and measure the free rotating force at this
1] Install nuts (28) and (29), matching time.
them to the grooves of differential Starting tangential force:
case (61). 10.1 – 19.4 N {1.03 – 1.98 kg}
2] Sling gear case (62) and install the
outer race to the bearing, then install
them to differential case (63).
3. Caps
1) Install caps (31) and (32) and tighten bolt
(30) temporarily.
2) Using tools [5] and [6], tighten bolt (21).
3 Bolt:
824 – 1,040 Nm {84 – 105 kgm}
5. Assembly of pinion and cage assembly

Assemble pinion and cage assembly (8)
according to the following procedure.
1) Assembly of cage assembly
Install bearing outer races (12b) and (14b)
to cage (13).
4. Adjusting preload on bearing

1) Rotate the adjustment rings (28) and (29)
with bar H6 until the ring gear reaches the
pinion gear and the backlash is elimi-
nated.
a Rotate the bearing sufficiently so that
it will come in contact with the other
contact surfaces and hit the ring gear
with a copper hammer, etc.
a Apply sufficient amount of oil to the
bearing.
a If you loosened either adjustment ring
by 1 turn, tighten the other one by 1
turn.
HM400-2 45
2) Assembly of pinion assembly

Install bearing inner race (12a) to pinion
(10).
a Install bearing inner race (12a) by
shrink fit or by using push tool [7].
4) Using push tool [8] and turning cage

assembly (9), install bearing inner race
(14a).
a Never push bearing inner race (14a)
with a press.
a Apply oil to bearing inner race (14a).
3) Erect pinion assembly (8) and insert

spacer (11) to pinion assembly and install
cage assembly (9).
46 HM400-2
5) Using tool H11, press fit oil seal (7). 7. Input coupling and holder
a Press fit oil seal (7) so that clearance Install coupling (2) and holder (1).
(c) between the periphery of oil seal 2 End of bearing (Part A):
(7) and cage (13) will be 10 ± 0.5 mm. Grease (G2-LI)
2 End of side seal (Part B):
Grease (G2-LI)
2 Holder mounting bolt: Adhesive (LT-2)
824 – 1,030 Nm {84 – 105 kgm}
6) Using tool H5, press fit side seal (5).

a Press fit side seal (5) so that its
periphery will be flush with cage (13).
6. Pinion and cage assembly

Set the standard shim (having the thickness
and quantity checked when disassembled) and
install pinion and cage assembly (3).
a Execute 8. "Adjusting tooth contact and
backlash", then determine the quantity
and thickness of the shims.
HM400-2 47
8. Adjusting tooth contact and backlash 2) Adjust the tooth contact according to the
q Adjust the backlash and tooth contact following procedure.
simultaneously. 1] Adjust the projection of the bevel pin-
1) Adjust the backlash according to the fol- ion with shim (65) between differential
lowing procedure. case (64) and transfer case (17).
1] Move the bevel gear with adjustment 2] Adjusting tooth contact
nuts (28) and (29). At this time, turn a See "Adjusting tooth contact" in
the nuts on both sides by the same 3) below
angle in the same direction so that
the preload on the bearing will not
change.
3) Adjusting tooth contact of bevel gear and

bevel pinion
q When the backlash is below standard
2] Apply dial gauge [11] perpendicularly value
to the reversing tooth surface at the Loosen the adjustment nut on the bevel
outer end of the bevel gear. Rotate gear side and tighten the adjustment nut
the adjustment nuts until the dial on the right side by the same angle (to
gauge indicates 0.3 - 0.4mm. move the bevel gear in the direction of A).
places and measure it with the q When the backlash is above standard
pinion fixed. value
Loosen the adjustment nut on the left side
and tighten the adjustment nut on the
bevel gear side by the same angle (to
48 HM400-2
(1) Checking tooth contact If bevel pinion is too close to bevel gear
Apply red lead thinly to the surfaces of 7 – a The tooth contact pattern is as fol-
8 teeth of the bevel gear and turn the lows.
bevel gear in the forward and reverse q Increase the shims of the bevel pinion
directions, then check the tooth contact to move the bevel pinion in direction
pattern on the bevel gear. (E).
a The center of the tooth contact must q Move the bevel gear in direction (F).
be as follows.
q Middle of tooth height
q Point on tooth at distance of (x) from
small end (C)
30 – 60% of the tooth length.

If bevel gear is too close to bevel pinion

lows.
q Decrease the shims of the bevel pin-
tion (C).
(2) Adjusting tooth contact

If the tooth contact pattern is not proper,
adjust the tooth contact according to the
procedure shown in the following page.
check the backlash again.
If bevel pinion is too far from bevel gear

lows.
q Decrease the shims of the bevel pin-
tion (C).
HM400-2 49
If bevel gear is too far from bevel pinion

lows.
(E).
9. Bevel gear supporting bolt

Install bevel gear supporting bolt (66).
a Bring the bolt end in contact with the back
of the gear, then return it by a half turn and
secure it with the locknut.
2 Bolt: Gasket sealant (LG-5)
3 Locknut:
196 – 245 Nm {20 – 25kgm}
50 HM400-2
HM400-2 51

© 2009 KOMATSU
All Rights Reserved
52 HM400-2
SEN01446-01
HM400-2

HM400-2 2001 and up

Power train, Part 3
Removal and installation of front final drive and brake assembly ................................................................... 2
Disassembly and assembly of front final drive and brake assembly............................................................... 4
Removal and installation of center final drive and brake assembly .............................................................. 17
Disassembly and assembly of center final drive and plate assembly ........................................................... 19
Removal and installation of rear final drive and brake assembly .................................................................. 28
Disassembly and assembly of rear final drive and brake assembly ............................................................. 30
Removal and installation of center axle assembly ........................................................................................ 40
Removal and installation of rear axle assembly............................................................................................ 43
HM400-2 1
Removal and installation of front 4. Front wheels

final drive and brake assembly 1 Sling the front wheels (2) temporarily, then
remove the mounting bolts and front wheels
Removal (2). [*1]
4 Front wheel assembly: 800 kg
1. Draining oil from front final drive case
Drain oil from the front final drive case.
2. Jacking up front frame

1) Jack up the front (sub) frame and support
it on stand [1], etc.
2) Using jack [2], raise the front axle support.
5. Drive shaft between front differential and

front final drive
Disconnect the front differential end of drive
shaft (3) between front differential and front
final drive. [*2]
3. Left fender
Lift of left fender (1).
2 HM400-2
6. Brake cooling tubes and brake drive hose Installation

Disconnect brake cooing tubes (4) 2 pieces
and brake drive hose (5). q Carry out installation in the reverse order to
removal.
[*1]
3 Front wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*2]
2 Mounting bolt of drive shaft between front
differential and front final drive:
Adhesive (LT-2)
3 Mounting bolt of drive shaft between front
differential and front final drive:
98 – 123 Nm {10 – 12.5 kgm}

cuit. For details, see Testing and adjusting,
"Bleeding air from brake circuit".
Refilling with oil

q Pour the specified oil in the final drive case to
the specified level.
7. Front final drive and brake and side drive necessary.
shaft assembly q Check the oil level in the hydraulic tank and
Lift off front final drive and brake and side drive add the specified oil to the specified level if
shaft assembly (6). necessary.
a When removing, take extreme care that
the spline at the center of the side drive
shaft will not come out.
4 Front final drive and brake and side
drive shaft assembly: 610 kg
HM400-2 3

front final drive and brake
assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1210 Fixture t 3 N Q
792T-427-1110 Fixture t 3 N Q
1
01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 N Q
J 2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
3 792T-422-1230 Push tool t 1 N Q
792-520-2110 Installer t 1
5 792-530-1600 Push tool t 1
790-434-1620 Installer t 1
Disassembly
1. Drive shaft (1)
Remove drive shaft (1).
a When removing the drive shaft, take care
that its cap (yoke) will not come off.
3. Place the assembly with the brake side down.
4. Sun gear
Remove sun gear (5).
2. Cover and shaft

Remove cover (2) and snap ring (3), then
remove shaft (4) toward the opposite side.
a Drain the oil remaining in the case.
a When removing snap ring (3), take
extreme care not to expand it too wide. If
the inside diameter of the removed snap
ring is larger than 51.4 mm or its level dif-
ference measured on a level place is
larger than 0.3 mm, do not use it again
(but replace it).
4 HM400-2
5. Carrier assembly 6. Thrust washer

1) Remove carrier assembly (6). Remove thrust washer (11).
2) Disassemble the carrier assembly accord- 7. Plate

ing to the following procedure. Using forcing screw [1], remove plate (12).
1] Remove shaft (7).
a Take care not to lose ball (8).
2] Remove planetary gear (9) and bear-
ing (10).
8. Retainer and shim

1) Using tools J1 secure inner gear (13) and
outer gear (14).
a Install tools J1 to 3 places equally
spaced on the periphery of inner gear
(13).
a Be sure to install tool J1 to protect the
floating seal before removing retainer
(15).
and shim.
HM400-2 5
9. Ring gear
Remove ring gear (16).
1) Disassemble the ring gear according to

1] Remove mounting bolts (17) and hold-
er (18).
2] Remove inner hub (20) from ring gear
(19).
11. Place the assembly with the brake side up.
12. Brake assembly

1) Remove brake assembly (24) from shaft
(23).
a Make match marks in advance.
10. Floating seal cage and floating seal

Remove floating seal cage (21) [including a
half part of floating seal (22a)].
a Use a forcing screw of M10 (long size) to
remove the floating seal cage.
6 HM400-2
2) Disassemble the brake assembly accord- 2> Remove seal rings (28) and (29)
ing to the following procedure. from cylinder (26) and piston (27).
1] Remove tools J1.
2] Remove cylinder assembly (25).
3) Remove damper (end plate) (30), plate

(31), and disc (32).
3] Disconnect the cylinder assembly a Check the position of notch of the plate.
1> Remove piston (27) from cylinder
(26).
HM400-2 7
13. Hub (Inner gear) and outer gear 3) Remove floating seal (37a) from floating
1) Remove outer gear (34) from hub (inner seal and cage assembly (36).
gear) (33).
4) Remove cover (39) from outer gear (38),

2) Remove floating seal and cage assembly then remove seal (40).
(36) and floating seal (22b) from hub
(inner gear) (35).Check the cut of the
plate.
5) Remove floating seal (37b) from outer

gear (38).
8 HM400-2
14. Shaft (Tube) assembly Assembly

Remove bearing inner race (42), retainer (43),
seal (44), and bushing (45) from shaft (tube) a If a tool for installing a seal is not specified (for
(41). the input shaft in particular), use a push tool of
1. Shaft (Tube) assembly

1) Install retainer (43) to shaft (tube) (41),
then using tool J4, install bearing inner
race (42).
2) Install bushing (45) and seal (44) to shaft

(tube) (41)
a Dimension (c) between shaft (tube)
end and seal end: 29 ± 0.2 mm
a Dimension (b) between shaft (tube)
mounting part and bushing end:
5 ± 0.2 mm.
HM400-2 9
2. Hub (Inner gear) and outer gear 4) Using tool J5, install floating seal (37a) to
1) Using tool J5, install floating seal (37b) to cage (46).
outer gear (38). a Measure height (A) at portion (a) of
the seal above the gear, hub, and
ratainer (at 4 places on the periphery)
and check that its dispersion is less
than 1 mm.
2) Using tool J2, install seal (40) to outer

gear (38).
5) Using tool J5, install floating seal (22b) to

hub (inner gear) (35).
3) Install cover (39) to outer gear (38).
6) Install floating seal and cage assembly

(36) to hub (internal gear) (35).
10 HM400-2
7) Install outer gear (34) to hub (inner gear) 2) Assemble the brake assembly according
(33). to the following procedure.
a Take extreme care that the floating 1] Assemble the cylinder assembly ac-
seal will not be damaged or rolled up. cording to the following procedure.
1> Install seal rings (28) and (29) to
cylinder (26) and piston (27).
3. Brake assembly
1) Install disc (32), plate (31), and damper
(end plate) (30).
a When installing the plate, match the 6
cuts on its per.
2> Install piston (27) to cylinder (26).
HM400-2 11
2] Install cylinder assembly (25). 4. Place the assembly with the brake side down.
3 Cylinder mounting bolt:
157 – 196 Nm {16 – 20 kgm} 5. Floating seal cage and floating seal
1) Using tool J5, install floating seal (22a) to
cage (21).
a Measure height (A) at portion (a) of
than 1 mm.
3] Install tools J1.
2) Install floating seal cage (21) {including a

half part of floating seal (22a)}.
3) Install brake assembly (24) to shaft (23).
12 HM400-2
6. Ring gear 7. Retainer and shim

1) Assemble the ring gear according to the 1) Adjust the preload on the bearing accord-
following procedure. ing to the following procedure.
1] Using tool J3, press fit bearing inner 1] Install retainer (15) with the bolts tem-
race (46) to inner hub (20). porarily without inserting any shim.
2] Remove tools J1 from 3 places and
tighten the bolts.
2]Install holder (18) and tighten mount-

ing bolts (17).
3 Holder mounting bolt: 3] Secure the brake assembly to forklift
27.5 – 34 Nm {2.8 – 3.5 kgm} [1] etc.
4] While rotating inner gear (13) by 20 –
30 turns, tighten 4 retainer mounting
bolts alternately and evenly.
a Tighten the retainer mounting
bolts evenly to 78.5 ± 4.9 Nm {8 ±
0.5 kgm}.
a If the retainer mounting bolts are
tightened without rotating the
inner gear (13), the bearing does
not fit and proper preload is not
applied to it.
2) Install ring gear (16).
HM400-2 13
5] Using depth micrometer [2], measure 8. Shaft

distance (c) between the ends of the Install shaft (4).
shaft and retainer (15).
a Measure the distance at 2 places
6] Remove retainer (15) and measure its
thickness (a). Obtain difference (b) =
(c – a) and add 0.3 mm to it and use
the result as the thickness of the
shim.
2) Put in the shims selected in the foregoing

section, install retainer (15) and tighten
the mounting bolts.
a Rotating inner gear (13), tighten the
mounting bolt evenly until the tighten-
ing torque becomes constant. 9. Plate
2 Threaded parts of retainer mount- Install plate (12).
ing bolt: Adhesive (LT-2)
3 Retainer mounting bolt:
157 – 196 Nm {16 – 20 kgm}
a After tightening the mounting bolts,
turn inner gear (13) and check that it
rotates normally.
14 HM400-2
10. Thrust wawher 2) Install carrier assembly (6).

Install thrust washer (11).
12. Sun gear

11. Carrier assembly Install sun gear (5) and snap ring (3).
1) Assemble the carrier assembly according a If the inside diameter of removed snap
to the following procedure. ring (3) is larger than 51.4 mm or its level
1] Install bearing (10) and planetary difference measured on a level place is
gear (9). larger than 0.3 mm, do not use it again.
2] Install shaft (7).
a Be careful not to forget to put ball
(8) in.
13. Cover
Install cover (2).
3 Cover mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
HM400-2 15
14. Drive shaft

Install drive shaft (1).
2 Threaded parts of retainer mounting
bolt: Adhesive (LT-2)
3 Drive shaft mounting bolt:
98 –123 Nm {10 – 12.5 kgm}.
16 HM400-2
Removal and installation of center

final drive and brake assembly 1
Removal
1. Draining oil from center final drive case
Drain oil from the center final drive case.
2. Jacking up center axle

Jack up the center axle.
3. Rear (Front) wheel

Sling the rear (front) wheels (1) temporarily
and remove the mounting bolts to remove rear
(front) wheels (1). [*1]
4 Rear (Front) wheel assembly: 800 kg Remove the center final drive cover and sun
gear and drive shaft (4).
4. Brake cooling tubes and brake drive hose

6. Center final drive assembly
Disconnect brake cooing tubes (2) 2 pieces
Lift off center final drive assembly (5).
and brake drive hose (3).
4 Center final drive assembly: 500 kg
HM400-2 17
Installation
removal.
[*1]
3 Rear wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

Refilling with oil

necessary.
necessary.
18 HM400-2

center final drive and plate
assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1210 Fixture t 3 N Q
792T-427-1110 Fixture t 3 N Q
1
01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 N Q
2 790-101-5421 Grip t 1
J
01010-51240 Bolt t 1
3 792T-422-1230 Push tool t 1 N Q
4 792T-422-1240 Push tool t 1 N Q
792-520-2110 Installer t 1
5 792-530-1600 Push tool t 1
790-434-1620 Installer t 1
Disassembly 3. Retainer and shim

1) Using tools J1, secure inner gear (6) and
a The sun gear was removed when the final drive outer gear (7).
and brake assembly was removed. a Install tools J1 to 3 places equally
spaced on the periphery of inner gear
1. Place the assembly with the brake side down. (6).
a Be sure to install tools J1 to protect
2. Carrier assembly the floating seal before removing
1) Remove carrier assembly (1). retainer (8).
and shim.

2] Remove planetary gear (4) and bear-
ing (5).
HM400-2 19
4. Ring gear

1] Remove mounting bolts (10) and
holder (11).
(12).

7. Brake assembly
1) Remove brake assembly (17) from shaft (16).

2) Disassemble the brake assembly accord-

1] Remove tools J1.
20 HM400-2

3] Disconnect the cylinder assembly (24), and disc (25).
according to the following procedure. a Check the cut of the plate.
(19).

from cylinder (19) and piston (20).
8. Hub (Inner gear) and outer gear

1) Remove outer gear (27) from hub (inner
gear) (26).
HM400-2 21
2) Remove floating seal and cage assembly 4) Remove cover (32) from outer gear (31),
(29) and floating seal (15b) from hub then remove seal (33).
(inner gear) (28).

gear (31).
3) Remove floating seal (30a) from floating

seal and cage assembly (29). 9. Shaft (Tube) assembly
Remove bearing inner race (35) and retainer
(36) from shaft (tube) (34).
22 HM400-2
Assembly 3) Install cover (32) to outer gear (31).


1) Install retainer (36) to shaft (tube) (34),
then install bearing inner race (35).

cage (36).
than 1 mm.

outer gear (31).


gear (31).
HM400-2 23
6) Install floating seal and cage assembly

2) Assemble the brake assembly according

1] Assemble the cylinder assembly ac-
7) Install outer gear (26) to hub (inner gear) cording to the following procedure.
(27). 1> Install seal rings (21) and (22) to
a Take extreme care that the floating cylinder (19) and piston (20).
seal will not be damaged or rolled up.
3. Brake assembly
(end plate) (23).
cuts on its periphery.
24 HM400-2
2] Install cylinder assembly (18).

157 – 196 Nm {16 – 20 kgm}

cage (14).
2) Install floating seal cage (14) [including a
than 1 mm.
HM400-2 25
6. Ring gear 3] While rotating inner gear (6) by 20 –

1) Assemble the ring gear according to the 30 turns, tighten 4 retainer mounting
following procedure. bolts alternately and evenly.
1] Using tool J3, press fit bearing inner a Tighten the retainer mounting
race (39) to inner hub (13). bolts evenly to 73.5 ± 0.98 Nm
{7.5 ± 0.1 kgm}.
applied to it.

ing bolts (10).
27.5 – 34 Nm {2.8 – 3.5 kgm}
4] Using depth micrometer [1], measure

distance (c) between the ends of the
shaft and retainer (8).
shim.
2) Set a shim of proper thickness and re-

tainer (8) and tighten the mounting bolts.
1) Adjust the preload on the bearing accord-
ing torque becomes constant.
2 Threaded parts of retainer mount-
1] Install retainer (8) with the bolts tem-
porarily without inserting any shim.
157 – 196 Nm {16 – 20 kgm}
tighten the bolts.
26 HM400-2
a After tightening the mounting bolts, rotate

inner gear (6) and check that it rotates
normally.
8. Carrier assembly
1] Install bearing (5) and planetary gear
(4).
(3) in.
a Install the sun gear when installing the fi-

nal drive and brake assembly.
HM400-2 27
Removal and installation of rear 2) Disconnect brake drive hose (3).

final drive and brake assembly 1
Removal
1. Remove the body assembly. For details, see
"Removal and installation of body assembly".
2. Draining oil from rear final drive case

Drain oil from the rear final drive case.
3. Jacking up rear axle

Jack up the rear axle.
4. Rear wheel
Sling the rear wheels (1) temporarily and 6. Sun gear and drive shaft
remove the mounting bolts to remove rear Remove the rear final drive cover and sun gear
wheels (1). [*1] and drive shaft (4).
4 Rear wheel assembly: 800 kg
7. Rear final drive and brake assembly

Lift off the rear final drive and brake assembly.
5. Brake cooling tubes and brake drive hose 4 Rear final drive and brake assembly:
1) Disconnect brake cooing tubes (2) 2
pieces. 500 kg
28 HM400-2
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
3 Rear wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}

Refilling with oil

necessary.
necessary.
HM400-2 29
Disassembly and assembly of 2] Remove planetary gear (4) and bear-

rear final drive and brake ing (5).
assembly 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1210 Fixture t 3 N Q
792T-427-1110 Fixture t 3 N Q
1
01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 N Q
J 2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
3 792T-422-1230 Push tool t 1 N Q
792-520-2110 Installer t 1
5 792-530-1600 Push tool t 1
790-434-1620 Installer t 1
Disassembly
a The sun gear was removed when the final
drive and brake assembly was removed.
1) Using tools J1 (Install them to 3 places on
the periphery, equally spaced), secure
inner gear (6) and outer gear (7).
a Be sure to install tools J1 to protect
2. Carrier assembly
the floating seal before removing
1) Remove carrier assembly (1).
retainer (8).
a Install tools J1 to 3 places on the pe-
riphery, equally spaced.
and shim.

30 HM400-2
4. Ring gear

1] Remove mounting bolts (10) and
holder (11).
(12).
7. Brake assembly
1) Remove brake assembly (17) from shaft
(16).

HM400-2 31
2) Disassemble the brake assembly accord- 2> Remove seal rings (21) and (22)
ing to the following procedure from cylinder (19) and piston (20).
1] Remove tools J1.

(24), and disc (25).
3] Disconnect the cylinder assembly a Check the cut of the plate.
(19).
32 HM400-2
8. Hub (Inner gear) and outer gear 3) Remove floating seal (30a) from floating
1) Remove outer gear (27) from hub (inner seal and cage assembly (29).
gear) (26).
4) Remove cover (32) from outer gear (31),

2) Remove floating seal and cage assembly then remove seal (33).
(29) and floating seal (15b) from hub
(inner gear) (28).

gear (31).
HM400-2 33
9. Shaft (Tube) assembly Assembly

Remove bearing inner race (35), retainer (36),
seal (37), and bushing (38) from shaft (tube) a If a tool for installing a seal is not specified (for
(34). the input shaft in particular), use a push tool of

Install retainer (36) to shaft (tube) (34), then
install bearing inner race (35).

outer gear (31).

gear (31).
34 HM400-2
3) Install cover (32) to outer gear (31). 6) Install floating seal and cage assembly

cage (36). 7) Install outer gear (26) to hub (inner gear)
a Measure height (A) at portion (a) of (27).
the seal above the gear, hub, and a Take extreme care that the floating
ratainer (at 4 places on the periphery) seal will not be damaged or rolled up.
than 1 mm.

HM400-2 35
3. Brake assembly
(end plate) (23).
cuts on its periphery.
2] Install cylinder assembly (18).

157 – 196 Nm {6 – 20 kgm}
2) Assemble the brake assembly according
1] Assemble the cylinder assembly
1> Install seal rings (21) and (22) to
cylinder (19) and piston (20).
36 HM400-2

cage (14).
2) Install floating seal cage (14) {including a
half part of floating seal (15a)}.
than 1 mm.
HM400-2 37
6. Ring gear 3] While rotating inner gear (6) by 20 –

1) Assemble the ring gear according to the 30 turns, tighten 4 retainer mounting
following procedure. bolts alternately and evenly.
1] Using tool J3, press fit bearing inner a Tighten the retainer mounting
race (39) to inner hub (13). bolts evenly to 73.5 ± 0.98 Nm
{7.5 ± 0.1 kgm}.
applied to it.

ing bolts (10).
27.5 – 34 Nm {2.8 – 3.5 kgm}
4] Using depth micrometer [1], measure

distance (c) between the ends of the
shaft and retainer (8)
shim.
2) Set a shim of proper thickness and re-

tainer (8) and tighten the mounting bolts.
1) Adjust the preload on the bearing accord-
ing torque becomes constant.
2 Threaded parts of retainer mount-
1] Install retainer (8) with the bolts tem-
porarily without inserting any shim.
157 – 196 Nm {16 – 20 kgm}
tighten the bolts.
38 HM400-2
a After tightening the mounting bolts, rotate

inner gear (6) and check that it rotates
normally.
8. Carrier assembly
1] Install bearing (5) and planetary gear
(4).
(3) in.
a Install the sun gear when installing

the final drive and brake assembly.
HM400-2 39
Removal and installation of center

axle assembly 1
Removal

2. Jacking up frame
1) Jack up the rear frame and support it on
stand [1], etc.
2) Using jacks [2] and [3], raise the center
5. Drive shaft between center differential and
axle and rear axle.
rear differential
Remove the guard and sling off drive shaft (8)
between the center differential and rear differ-
ential. [*2]
3. Rear (Front) wheels

Sling both rear (front) wheels temporarily, then
remove the mounting bolts and rear (front)
wheels (1). [*1]
4 Rear (Front) wheel assembly: 800kg differential
differential end of drive shaft (9) between the
hitch frame and center differential and sling
and fix it to the rear frame. [*3]
4 Drive shaft between hitch frame and
center differential:85 kg
4. Piping and harnesses

Disconnect differential lock hoses (2) – (4),
pieces, and rear retarder oil temperature sen-
sor connector (CN-T13) (7).
40 HM400-2
7. Lateral rod Installation

Remove lateral rod (10) [*4]
4 Lateral rod: 60 kg moval.
8. Equalizer bar spring [*1]

Remove equalizer bar spring (11). [*5] 3 Center wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*2]
Adhesive (LT-2)
98 – 123 Nm {10 – 12.5 kgm}
9. Center axle and arm assembly [Target: 113 Nm {11.5 kgm}]
1) Sling center axle and arm assembly (12)
temporarily. [*3]
a When installing the lateral rod, match tap hole
(a) to the center line of bearing (15) as shown
in Fig.
2) Remove holder plate (13) of the center

axle arm support, then remove center axle
and arm assembly (12) down.
4 Center axle and arm assembly:
2,200kg
HM400-2 41
[*4]
a Install the center axle and arm assembly so
that dimensions (X), (Z) and (Y) will be as fol-
lows.
Distance (X) between rear suspension cylinder
pins: 574 mm
Distance (Z) between rear axle top and rear
frame bottom: 130 mm
Distance (Y) between rear frame top and
equalizer spring top: 201 mm

a Adjust the suspension cylinder length. For de-
tails, see Testing and adjusting, "Testing and
adjusting suspension cylinder".
Refilling with oil

necessary.
necessary.
42 HM400-2
Removal and installation of rear

axle assembly 1
Removal

2. Jacking up frame
1) Jack up the rear frame and support it on
stand [1], etc.
2) Jack up the center axle and rear axle with
5. Drive shaft between center differential and
jacks [2] and [3].
rear differential
Remove the guard and sling off drive shaft (8)
between the center differential and rear differ-
ential. [*2]
3. Rear (Rear) wheels

Sling both rear (rear) wheels temporarily, then
remove the mounting bolts and rear (rear)
wheels (1). [*1]
6. Lateral rod
4 Rear (Rear) wheel assembly: 800 kg Remove lateral rod (9). [*3]
4 Lateral rod: 60 kg
4. Piping and harnesses

Disconnect differential lock hoses (2) – (4),
pieces, and rear brake oil temperature sensor
connector (CN-T13) (7).
HM400-2 43
7. Bracket (left) 3) Pull out lower pin (14) of rear suspension

Remove bracket (left) (10). cylinder (13) and remove rear axle and
arm assembly (11) down. [*4]
4 Rear axle and arm assembly:
2, 200 kg
8. Rear axle and arm assembly

1) Sling rear axle and arm assembly (11)
temporarily.
2) Remove holder plate (12) of the rear axle

arm support pin.
44 HM400-2
Installation [*4]
a Install the center axle and arm assembly so
q Carry out installation in the reverse order to re- that dimensions (X), (Z) and (Y) will be as fol-
moval. lows.
[*1] pins: 574 mm
3 Rear wheel mounting bolt: Distance (Z) between rear axle top and rear
824 – 1,030 Nm {84 – 105 kgm} frame bottom: 130 mm
[Target: 926 Nm {94.5 kgm}] Distance (Y) between rear frame top and
[*2]
Adhesive (LT-2)
98 – 123 Nm {10 – 12.5 kgm}
[*3]
(a) to the center line of bearing (15) as shown k After installing, bleed air from the brake cir-
in Fig. cuit. For details, see Testing and adjusting,

Refilling with oil

necessary.
necessary.
HM400-2 45

© 2007 KOMATSU
All Rights Reserved
46 HM400-2
SEN01447-02
HM400-2

HM400-2 2001 and up

Undercarriage and frame
Removal and installation of front suspension cylinder assembly .................................................................... 2
Removal and installation of rear suspension cylinder assembly..................................................................... 4
Removal and installation of equalizer bar assembly ....................................................................................... 5
Removal and installation of front wheel assembly .......................................................................................... 7
Removal and installation of rear front wheel assembly................................................................................... 8
Removal and installation of rear rear wheel assembly ................................................................................... 8
Removal and installation of hitch frame assembly .......................................................................................... 9
Disassembly and assembly of hitch frame.................................................................................................... 15
Removal and installation of body assembly .................................................................................................. 18
HM400-2 1
Removal and installation of front

suspension cylinder assembly 1
Removal
1. Jacking up
1) Jack up the front (sub) frame and support
it on stand [1], etc.
2) Using jack [2], raise the front axle support.
a Check that the front frame is jacked up.

Referring to Testing and adjusting, "Test-
ing and adjusting suspension cylinder",
release the nitrogen gas from the front
suspension cylinder.
4. Front suspension cylinder

1) Remove the cover and disconnect grease
tube (3).
2. Left fender 2) Remove upper and lower pins (4) and (5)
Lift off left fender (1). and front suspension cylinder assembly
(6). [*2]
3. Front wheels
Sling the front wheels (2) temporarily, then
(2). [*1]
2 HM400-2
Installation
moval.
[*1]
3 Front wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[*2]
HM400-2 3
Removal and installation of rear 3. Rear suspension cylinder

suspension cylinder assembly 1 Using balancing rod [3], etc., remove upper
and lower pins (3) and (4) and rear suspension
Removal cylinder assembly (5). [*2]
a Release nitrogen gas from the rear suspension

cylinder. For details, see Testing and adjust-
ing, "Testing and adjusting suspension cylin-
der".
1. Jacking up
1) Jack up the rear frame and rear axle with
jacks [1] and [2].
2) Lower lateral rod (1) and pull it out toward
you. [*1]
k Since the lateral rod cannot be slung, se-

cure it (with a rope, etc.) and remove it,
watching your steps carefully.
4 Lateral rod: 60 kg Installation
removal.
[*1]
(a) to the center line of bearing (15) as shown
in figure.
2. Bracket
Remove bracket (2).
[*2]
4 HM400-2
Removal and installation of 3) Remove rod pin (3) and hoist cylinder (4).
equalizer bar assembly 1 [*2]
4 Hoist cylinder: 230 kg
Removal
k Open the manual valve in the hydraulic tank
to release the internal pressure.
k Loosen the oil filler cap to release the
remaining pressure from the hydraulic tank.
1. Release the nitrogen gas.

q Release nitrogen gas from the rear sus-
pension cylinder. For details, see Testing
and adjusting, "Testing and adjusting sus-
pension cylinder". [*1]

"Removal and installation of body assembly". 4. Remove the rear wheels (front and rear) on the
side from which the equalizer bar will be
3. Remove the hoist cylinder. removed. For details, see "Removal and
1) Disconnect hoses (1) and (2) installation of rear wheel assembly".
a Plug the hoses to prevent the oil from
flowing out. 5. Remove bottom pin (5) of the rear suspension
k Pull the hoist cylinder toward inside cylinder and bring cylinder (6) down toward the
of the machine body in advance. (If rear of the vehicle body.
the rod pin is removed, the hoist
cylinder falls (swings). Accord-
ingly, be sure to pull the cylinder
toward inside of the machine body
in advance.)
6. Remove 4 mounting bolts (8) of the equalizer

bar above cushion (7).
2) Sling the hoist cylinder temporarily and

bring it down at a right angle to vehicle
body.
HM400-2 5
7. Sling the equalizer bar temporarily. Installation

8. Remove 6 mounting bolts (10) of plate (9) at q Carry out installation in the reverse order to
the center of the equalizer bar. [*3] removal.
9. Using forcing screw [1], remove bushing (11). [*1]

Refill the rear suspension cylinder with nitrogen
gas. For details, see "Testing and adjusting sus-
pension cylinder".
[*2]
3 Rod pin: 157 – 196 Nm {16 – 20 kgm}
[*3]
a When installing, measure the distances (a), (b)
and (c) between the machine body and equal-
izer bar and adjust the difference between dis-
tances (a) and (b) and between (c) and (d) will
not exceed 2 mm respectively.
3 Plate
10. Lift off equalizer bar (12). Diameter of thread: 24 mm:
4 Equalizer bar: 220 kg 824 – 1,030 Nm {84 – 105 kgm}
Diameter of thread: 14 mm:
157 – 196 Nm {16 – 20 kgm}
a Install so that dimensions (X), (Z) and (Y) will
be as follows.
pins: 574 mm
Distance (Z) between rear axle top and rear
frame top: 130 mm
Distance (Y) between rear frame top and
Adjusting body
a Adjust the body positioner. For details, see
Testing and adjusting, "Adjusting body posi-
tioner".
Refilling with oil

a Add engine oil (TO10) up to the specified level
and start the engine. Raise and lower the body
2 to 3 times to check the oil level again.
6 HM400-2
Removal and installation of front Installation

wheel assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Jacking up [*1]
1) Jack up the front (sub) frame and support 3 Front wheel mounting bolt:
it on stand [1], etc. 824 – 1,030 Nm {84 – 105 kgm}
2) Using jack [2], raise the front axle support. [Target: 926 Nm {94.5 kgm}]
2. Left fender
Lift off left fender (1).
3. Front wheels
Sling the front wheels (2) temporarily, then
(2). [*1]
HM400-2 7
Removal and installation of rear Removal and installation of rear

front wheel assembly 1 rear wheel assembly 1
Removal Removal
1. Draining oil from center final drive case 1. Remove the body assembly, referring to
Drain the oil in the center final drive case. "Removal of body assembly".
a When using a forklift truck for removal, the
2. Jacking up center axle work in this item may be skipped over.
Jack up the center axle.
2. Jacking up rear axle
3. Rear front wheel Jack up the rear axle.
Sling the rear front wheel temporarily and
remove the mounting bolts to detach rear front 3. Rear rear wheel
wheel (1). [*1] Sling the rear rear wheel temporarily and
4
remove the mounting bolts to detach rear rear
Rear front wheel assembly: 800 kg.
wheel (1). [*1]
4 Rear rear wheel assembly: 800 kg
Installation
Installation
removal.
[*1] removal.
3 Rear front wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm} [*1]
[Target: 926 Nm {94.5 kgm}] 3 Rear rear wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
8 HM400-2
Removal and installation of hitch 2. Parking brake assembly

frame assembly 1 1) Release the parking brake.
2) Remove pad expansion spring bracket
Removal (12). [*2]
3) Remove the mounting bolts of plate (13)
k Disconnect the cable from the negative (–) and parking brake and cylinder assembly
terminal of the battery. (14).
pin.
1. Piping, hoses, and wiring harnesses

1) Disconnect hoist cylinder hoses (1) and
(2), differential lock hose, brake hoses (3)
– (6), brake cooling hoses (7) and (8), and
parking brake hose (9). [*1]
2) Disconnect joint connectors (CN-J015)
(10) and (CN-J013) (11) and differential
lock connector (CN-B36).

differential
Remo ve the guar d a nd d ri ve sh aft ( 15)
between the hitch frame and center differential.
[*3]
4 Drive shaft between hitch frame and
center differential: 80 kg
HM400-2 9
4. Parking brake disc and coupling assembly 7. Steering cylinder

Remove the coupling holder, then remove Remove head pin (19) and disconnect steering
parking brake disc and coupling assembly (16) cylinders (20) (on both sides). [*6]
[*4]
4 Parking brake and coupling assembly :
55 kg
8. Jacking up vehicle body

1) [Front operator's cab side]
1] Sling the front part with a crane (chain
[1])
5. Parking brake bracket. 2] Place a stand under the rear frame
Remove parking brake bracket (17). for safety.
4 Parking brake bracket : 55 kg
2) [Rear body side]

1] Support the rear body end with block
6. Drive shaft between transmission and hitch
[2] etc.
frame
2] Support the front frame with a jack,
Remove the guard. Sling and disconnect the
etc. for safety.
transmission end of drive shaft (18) between
the transmission and hitch frame. [*5]
4 Drive shaft between transmission and
hitch frame: 55 kg
10 HM400-2
9. Hinge pins
1) Align the hinge pins by finely moving the
rear part of the front frame and the front
part of the rear frame up and down with
jacks [3] and [4].
10. Disconnection of front and rear sections

Hold the front part of the front frame with a
forklift and a crane and move it forward to dis-
connect from the rear frame.
2) Remove plate (21) and pin lock plate k Keep the level of the sections around
(21A) and remove (pull down out) upper the pins in the forward-backward direc-
hinge pin (22). tions until the rear part of the front
3) Remove pin bushing (21B) upward. f rame is separated f rom th e hit ch
4) Remove (pull up out) lower hinge pin (23) frame.
with a jack etc. [*7] k Check that there are clearances (a) and
(b) between the rear part of the front
frame and the hitch frame, and then
disconnect the front frame from the
rear frame.
k Move the rear part of the front frame
forward together with a stand under it
until it is separated from the hitch
frame so that it will be supported on
the stand at any time.
HM400-2 11
11. Hitch frame assembly

1) Remove rear seal and retainer (large) as-
sembly (24). [*8]
2) Using forcing screw [5], remove end re-

tainer (25). [*9]
3) While pulling out hitch frame assembly

(26) forward, lift it off.
a When pulling out the hitch frame
assembly forward, hold bearing inner
race (26a) so that it will not fall.
a Push out the side end of hitch frame
(26) forward with a thin and small
puller etc., and the hitch frame will be
pulled out easily.
a After pulling out the hitch frame half-
way, increase the number of slings
(change the slinging position) so that
the hitch frame will be balanced when
lifted off.
12 HM400-2
Installation [*7]
a Install the hinge pin in the following steps.
q Carry out installation in the reverse order to re- 1) Set bushing (58) to the front frame.
moval 2) Set bushing (35) to the hitch frame and
match the articulation center (position of
[*1] center pin) by moving the front frame
a Bleed air from the brake circuit. For details, assembly to the rear.
2 Dust seal lip face: Grease (G2-LI)
see Testing and adjusting, "Bleeding air from
brake circuit". 3) Insert lower hinge pin (34) from above.
2 Dust seal lip face: Grease (G2-LI)
2 Bearing inside perimeter:
[*2]
a Test the wear of the brake pad and adjust the Lubricant containing molybdenum
brake pad clearance. For details, see Testing disulfide (LM-P)
and adjusting, "Testing wear of parking brake 4) Install 2 O-rings (33).
2 O-ring: Grease (G2-LI)
pad".
5) Measure thickness (f) of retainer (30).
[*3] 6) Insert upper hinge pin (31) from below.
2 Dust seal lip: Grease (G2-LI)
a Before installing, check that the yoke of drive
2 Upper hinge pin outside perimeter:
shaft between the hitch frame and center dif-
ferential and the yoke of drive shaft between Lubricant containing molybdenum
center differential and rear differential are disulfide (LM-P)
shifted from each other by 45° ± 6°. 7) Assemble bushing (32) from above.
8) Assemble retainer (30) by tightening the
frame and center differential: mounting bolt (52).
Adhesive (LT-2)
245 – 309 Nm {25.0 – 31.5 kgm}
frame and center differential: a After confirming thorough running-in of
157 – 198 Nm {16 – 20 kgm} each contact surface, tighten mounting
[Target: 177 Nm {18 kgm}] bolt (52) again to the specified torque.
9) Measure dimension (gg) with clearance
[*4] between top of retainer (30) and the front
2 Coupling spline: LM-G frame at 3 points.
2 Coupling bolt: Adhesive (LT-2) 10) Select appropriate shims and assemble
3 Coupling bolt: them in so that the total shim thickness is
824 – 1,030 Nm {84.0 – 105.0 kgm} (g), i.e. the difference between (gg) and (f)
dimensions (g = gg – f) minus 0.08 to 0.18
[*5] mm.
a When installing the drive shafts, check that 0.08 < g = gg – f < 0.18 (mm)
convex section on the spider cap completely q Kind of shim thickness:
engages with groove of the counter yoke, and 0.1 mm and 0.5 mm
then tighten the mounting bolts. Standard shim thickness: 2 mm
2 Mounting bolt of drive shaft between trans-
q
11) Install a combination of the selected shims
mission and hitch frame: Adhesive (LT-2) to retainer (30) and tighten retainer mount-
3 Mounting bolt of drive shaft between trans-
ing bolts (52) and (53).
mission and hitch frame:
157 – 198 Nm {16 – 20 kgm} Liquid adhesive (LT-2)
245 – 309 Nm {25.0 – 31.5 kgm}
[*6]
k When aligning the pinholes, never put a fin-
ger into the hole.
HM400-2 13
3) Measure dimension (d) with a micrometer.

4) Rotate hitch frame (37) by 5 – 6 turns,
then repeat steps 2) and 3) above.
a Repeat steps 2) – 4) above until
dimension (d) is stabilized.
5) Combine shims so that difference (e) of
the measured values = (d – t) will be 0 –
0.15 mm.
6) After finishing the above adjustment, tight-
en all mounting bolts (36) to the following
torque.
3 Mounting bolt:
385 Nm {39.25 kgm} (Target)
[*8]
a When installing rear seal (27) to rear retainer
(28), use push tool [6] matched to the diameter
of the seal.
[*9]
a Procedure for adjusting bearing of oscillation
section
1) Measure thickness (t) of end retainer (25)
at 2 places (equally spaced on the periph-
ery).
2) Tighten mounting bolts (36) (3 pieces) to
the following torque without inserting shim
(29).
3 Mounting bolt: 68.6 Nm {7 kgm}
14 HM400-2
Disassembly and assembly of 3. Center shaft

hitch frame 1 1) Remove center shaft and bearing assem-
bly (8) from hitch frame (7).
Disassembly
1. Coupling
Remove coupling holder (1) and coupling (2).
2) Remove rear bearing (10) and front bear-

ing inner race (11a) from center shaft (9).
2. Rear retainer
1) Using forcing screw [1], remove retainer
assembly (3).
4. Disassembly of hitch frame

1) Remove front cage assembly (13), ring
(14), front bearing outer race (11b), and
rings (15) and (16) from hitch frame (12).
2) Remove ring (5), dust seal (6), grease fit- 2) Remove dust seal (18) from front cage
ting (19), and nipple (20) from rear retainer (17).
(4).
HM400-2 15
Assembly 3. Installation of center shaft and bearing as-

sembly
a If a tool for installing a seal is not specified (for Install the center shaft and bearing assembly
the input shaft in particular), use a push tool of (8) to hitch frame (7) carefully from rear.
a proper size for each part. a At this time, press fit rear bearing (10) to
hitch frame (7), too.
2 Fill the inside space of rear bearing
1. Center shaft
Using the push tool, press fit rear bearing (10) (10) with grease [Part D: 100 %
and bearing inner race (11a) to center shaft pack (85 g)].
(9). a Fill with grease: G2-LI (For part D, see 2
above.)
2. Assembly of hitch frame

Install ring (15) and front bearing outer race
(11b) to the front side of hitch frame (12).
Install ring (16) to the rear side of the hitch
frame (12).
2 Fill the inside space of ring (15) with
grease [Part A: 100 % pack (127 g),
Part B: 100 % pack (147 g)].
2 Fill the inside space of front bearing out-
er race (11b) with grease [Part C: 100 %
pack (123 g)].
2 Fill the inside space of rear bearing (10)
with grease [Part D: 100 % pack (85 g)].
a Fill with grease: G2-LI
16 HM400-2
4. Ring and front cage assembly 6. Rear retainer

1) Install ring (14) to hitch frame (12). 1) Press fit dust seal (6) to rear retainer (4).
2) Install dust seal (18) and O-ring to front 2 Lip: Grease (G2-LI)
cage (17), then install front cage (13) to 2) Install ring (5) and O-ring to rear retainer
hitch frame (12). (4).
2 Apply grease to the lip of dust seal a Fill the groove of the ring with grease
(18). of about 85 g.
2 Fill the inside space of dust seal 2 Groove of ring: Grease (G2-LI)
(18) with grease [Part F: Full pack 3) Install nipple (20) and grease fitting (19) to
(25 g), Part E: 100 % pack (123 g)]. rear retainer (4).
a Fill with grease: G2-LI 4) Install rear retainer assembly (3).
a Supply grease of 200 g to the retainer
through the grease fitting (19).
2 Inside of retainer: Grease (G2-LI)
5. Coupling
Install coupling (2) and coupling holder (1).
2 Coupling spline: LM-G
3 Coupling bolt:
824 – 1,030 Nm {84.0 – 105.0 kgm}
HM400-2 17
Removal and installation of body 3. Sling the body temporarily.

assembly 1
4. Disconnect body potentiometer linkage (2)
Removal from the body.
1. Remove right and left hoist cylinder rod pins (1). 5. Remove body hinge pins (3) on both sides. [*2]
[*1]
a Sling the bottom of the hoist cylinder.
a After removing pin (1) from each cylinder
rod, pull the hoist cylinder toward the
machine body with lever block [1] to pre-
vent it from falling down.
k If rod pin (1) is removed, the hoist cyl-
inder falls outward. Accordingly, be
sure to pull the cylinder toward inside
of the machine body in advance.
6. Lift off body assembly (4). [*3]

4 Body assembly: 4,450 kg
2. While loosening lever block [1], lower the

crane to place the bottom of the hoist cylinder
on the tire.
a Place block (2) between the bottom of the
hoist cylinder and tire.
a Pull the hoist cylinder toward the machine
body with lever block [1] to prevent it from
falling down.
18 HM400-2
Installation [*2]
a When installing the body hinge pin, check the
q Carry out installation in the reverse order to thickness and quantity of the shims.
3 Body hinge pin:
removal.
157 – 196 Nm {16 – 20 kgm]
[*1]
k "Open" manual valve (9) installed to hy- [*3]
draulic tank (8) and align the pin holes with q Adjustment of body mount shims
a bar etc. After aligning the pin holes, be 1) Install spacer (5) 58 mm high to the end of
sure to close the manual valve. body (4). (1 place on each side)
2) Measure clearance (a) between the center
Procedure for "opening" manual valve of the mounting part of bottom mount (6)
1) Loosen locknut (9a). and frame top (7).
2) Rotate shaft (9b) counterclockwise to a Measure at (A), (B), and (C) on both
"Open" the valve. side, 6 places in total.
3) Rotate shaft (9b) clockwise and fix it with
locknut (9a).
3 Bottom pin (Diameter of thread: 14 mm):

157 – 196 Nm {16 – 20 kg}
3) Calculate the thickness of the shims to be

installed to each part.
a Thickness of shims = (a – 26) mm
4) Insert shims of the calculated thickness.
a Standard thickness of shims: 4 mm
5) Lower the body and check that all of the 6
parts of the bottom mount are in contact
with the frame top.
6) After installing the body, adjust the body
positioner sensor.
a For details, see Testing and adjusting
volume, "Adjusting body positioner
sensor".
HM400-2 19

© 2009 KOMATSU
All Rights Reserved
20 HM400-2
SEN01448-02
HM400-2

HM400-2 2001 and up

Hydraulic system
Disassembly and assembly of steering valve ................................................................................................. 2
Removal and installation of flow amplifier valve assembly ........................................................................... 12
Removal and installation of hoist valve assembly......................................................................................... 14
Disassembly and assembly of hoist valve assembly .................................................................................... 16
Disassembly and assembly of steering cylinder assembly ........................................................................... 18
Disassembly and assembly of hoist cylinder assembly ................................................................................ 24
HM400-2 1
Disassembly and assembly of steering valve 1

Component parts
Tools needed for disassmbly and assembly

q Torque wrench (torque capacity: 49 Nm {5 kgm}) q Plastic hammer
q 5/12 in - 12 point socket q Small amount of grease
q Flat-headed screwdriver (large) q Vise
q Flat-headed screwdriver (small) q Oil-based felt pen
q Spring insertion tool (P/N: 600057) q Tweezers
q 3/16 in hexagonal wrench
2 HM400-2
Parts list
Part No. Part name Q‘ty Remarks
1 Screw 6
2 Retainer screw assembly 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
6 Spacer (1)
7 Spacer plate 1
8 Drive 1
9 Housing 1
10 Sleeve 1
11 Spool 1
12 Pin 1
Centering spring 6 For standard input torque specification
13
Centering spring 4 For low input torque specification
14 Flat spring (2) Only for low input torque specification
15 Race bearing 1
16 Thrust needle 1
17 O-ring 1
18 Oil seal 1 X-ring or Teflon seal
19 Dust seal 1
20 Retaining ring 1
21 Seal gland bushing 1
22 O-ring 2 Part No.: 5776
23 O-ring 1 Part No.: BA0098A
24 Inlet check valve sub assembly 1 (Cannot be disassembled)
25 Valve seat 1 (Cannot be disassembled)
26 Poppet 1
27 Spring 1
28 Plug 1
29 O-ring 1
30 Retainer plug 2
31 Spring 2
32 Ball 2
33 Valve seat 2 (Cannot be disassembled)
34 Ball 2
35 Ball holder 2
36 Spring 2
37 Plug 2
38 O-ring 2
39 Adapter screw 1
40 Ball 1
41 Name plate 1
42 Rivet 2
Seal kit (X-ring) Part No.: BA0271A

Seal kit (Teflon seal) Part No.: BA0273A
HM400-2 3
Disassembly 3. Remove spacer (5) inside spline on inside of

star of Gerotor (4).
a When disassembling the valve, cleanliness is Remove Gerotor (4). Be careful not to drop
extremely important. Carry out the work in a star from ring of outer cicumference of Gerotor.
clean place. Remove O-ring (22) from Gerotor.
a In the following explanation diagrams, it is not
absolutely necessary to hold the unit in a vise,
but it is recommended to use a vise as far as
possible.
k Be extremely careful not to injure yourself
on the edges of sleeves, spool, housing,
and other machined parts.
1. Put end cap (3) at the top, fit side face of hous-
ing between copper sheets in vise [8], and be
careful not to tighten vise too strongly.
4. Remove drive (8), then remove spacer plate

(7). Remove O-ring (23) from housing.
2. Remove 6 screws (1) and 1 retainer screw (2),

then remove end cap (3). Remove O-ring (22)
from end cap (3).
5. Using flat-headed screwdriver, remove adapter

screw (39). Remove housing from vise, set
upside down, then remove ball (40).
a Be careful not to drop or lose the ball.
4 HM400-2
6. Set housing upside down, remove 2 springs a When removing the seal, be careful not to
(31), 2 retainer plugs (30), and 2 balls (32). damage the seal gland bushing.
a Be careful not to drop or lose the parts.
9. Remove 2 race bearings (15) and thrust nee-

7. Set on clean cloth with flange surface of hous- dle (16).
ing facing up to prevent damage to finished
surface. Use flat-headed screwdriver to raise
tip of retaining ring (20), then remove from
housing.
k The retaining ring may fly out from the
housing, so always wear protective
glasses.
10. Push spline portion inside spool with thumb

and remove spool and sleeve assembly from
opposite side of housing flange. When doing
this, be careful not to let outside diameter of
sleeve get caught in inside diameter of hous-
ing.
a Depending on the assembly of sleeve and
8. Set housing on clean cloth with axial line of spool, it may not work properly if it is
valve horizontal. Turn spool and sleeve assem- assembled 180° from the proper direction,
bly to set sleeve pin in horizontal position, then so make marks to show the position of
push out spool and sleeve assembly slightly, spool and sleeve (43). Remove pin (12).
and remove seal gland bushing (21) from k Center spring (13) may jump out of the
housing. spool. Accordingly, be sure to put on
Remove oil seal and dust seal from gland safety glasses.
bushing.
HM400-2 5
11. Push out spool inside sleeve slightly, and 14. Disassembly of overload relief valve
remove centering spring (13) carefully by hand Using hexagonal wrench (width across flats: 3/
from spool. 16 inch), remove plug (37) 2 places. Remove
O-ring (38) from plug. Using tweezers, remove
2 springs (36), 2 ball holders (35), and 2 balls
(34).
a The valve seat is stuck to the housing and
cannot be removed.
12. Rotate spool slowly and pull out spool (11)

from sleeve (10). Remove O-ring from hous-
ing.
13. Disassembly of steering relief valve

Using hexagonal wrench (width across flats: 3/
16 inch), remove plug (28). Remove O-ring
(29) from plug. Using tweezers, remove spring
(27) and poppet (26).
a The valve seat is stuck to the housing and
cannot be removed.
6 HM400-2
Assembly k The centering spring may fly out from the

spool, so always wear protective glasses.
a Check all the joining parts.
Parts with gouges or burrs will cause leakage
of oil, so replace them with new parts.
Wash all metal parts with clean solvent and
blow dry with compressed air. If they are wiped
with rags or paper, pieces of cloth or paper will
stick to the parts or get inside the valves. This
will cause the hydraulic system to become
dirty, so do not wipe with cloth or paper.
Do not polish parts with sandpaper or modify
with a file.
k Be extremely careful not to injure yourself
on the edges of sleeves, spools, housing,
and other machined parts.
a As a basic rule, assemble new O-rings and 3. Set housing on clean cloth with axial line of
seal after disassembling. Coat the O-rings with valve horizontal. Insert spool and sleeve
a small amount of clean grease before assem- assembly from opposite end of housing to
bling. flange end. In this condition, check that spool
a The O-rings in front of or behind the spacer and sleeve assembly rotates smoothly inside
plate are of very similar sizes, so check the housing.
part number before opening the seal kit, and a When inserting spool and sleeve assem-
be extremely careful not to mix them. bly, be careful not to insert it at an angle
and get it caught. Keep the pin at near the
1. Turn spool (11) and insert slowly into sleeve horizontal postion, and rotate slightly to
(10). Grip spline portion of spool and check left and right to insert.
that spool rotates smoothly inside sleeve. Align a Insert so that the end face of the spool
mark made when disassembling. and sleeve assembly is level with the end
face of the housing. If it is inserted further,
the pin will fall inside the housing, so stop
inserting when the end face is level.
2. Align 2 spring grooves st 180° in spool and

sleeve, then stand on a horizontal plate. Insert
spring insertion tool (Part No.: 600057) in
spring groove, then fit centering spring to
insertion tool so that notched portions at both
ends are at bottom.When doing this, it is easier
to insert if spool is lifted up slightly from sleeve.
Hold centering spring at opposite end with a
finger and compress it to push it into spool
sleeve groove. When doing this, slide insertion
tool at same speed as pushing in spring. After
inserting, align end of spring with outside diam-
eter of sleeve. Insert sleeve pin into hole in
sleeve, and align both ends of pin with outside
diameter of sleeve.
HM400-2 7
4. Place housing on clean flat surface, then a The diagram below is the standard seal
assemble O-ring (17). specification drawing.
Assemble 2 race bearings (15) and thrust nee-
dle (16). Always insert thrust needle between
race bearings.
6. After assembling seals, rotate seal gland bush-

ing (21) and insert to spool. Tap with plastic
hammer to insert to specified position.
5. Assemble dust seal (19) to seal gland bushing Assemble retaining ring (20) to housing.
(21). Assemble dust seal so that flat surface is a Push open with a flat-headed screwdriver
at seal gland bushing end. Assemble oil seal so that the whole circumference of the
(18) to seal gland bushing. retaining ring fits securely in the groove in
a There are two types of seal: Teflon seal the housing.
and standard seal. k The retaining ring may fly out from the
a Assemble the oil seal carefully so that housing, so always wear protective
there is no twisting or deformation. glasses.
a The diagram below is the Teflon seal
specification drawing; (44) is the distin-
guishing groove.
a Seal assembly drawing

Screwdriver [9], dust seal (19), retaining
ring (20), seal gland bushing (21), oil seal
(18), O-ring (17).
8 HM400-2
7. Assembly of steering relief valve 9. Assembly of anti-cavitation check valve

Assemble O-ring (29) to plug (28). Grip the port surface and side surface of the
Using tweezers, assemble spring (27) and housing lightly in a vise. Fit copper sheets in
poppet (26) to housing. Using hexagonal the vise, and be careful not to tighten the vise
wrench (width across flats: 3/16 inch), assem- too strongly.
ble plug (28) to housing. Of the 7 bolt holes in the end face of the hous-
ing, insert 1 each of spring (31), retainer plug
(30), and ball (32) in the 2 holes shown in the
drawing.
a Be careful not to drop or lose the ball.
a Be careful of the assembly direction of the
retainer plug.
8. Assembly of overload relief valve

Assemble O-ring (38) to plug (37). Fit grease
to ball holder (35) and install ball (34). Using
tweezers, assemble ball holder (35) and spring
(36) to housing. Using hexagonal wrench
(width across flats: 3/16 inch), assemble plug
(37) to housing. 10. Assembly of gerotor
a The size of the overload valve ball and the Lightly hold the housing by sides (45) of the
anti-cavitation check valve ball is different, ports section with a vise (the part 25 mm wide
so be careful not to mix them. to hold with the vise). Apply copper plates etc.
to the vise and take care not to tighten too
strongly.
HM400-2 9
11. Of the 7 bolt holes in the end face of the hous- 14. Assemble O-ring (22) to Gerotor (4).
ing, insert ball (40) in the holes shown in the
drawing. Assemble adapter screw (39) in holes
in same drawing.
15. Set the O-ring side of the gerotor end face to

spacer plate (7) side. While matching roots
(48) of the gerotor star teeth to the line drawn
12. Assemble O-ring (23) to housing. on the end face of drive (8) matched to pin
Set spacer plate (7) on top and align position (12), install the gerotor.
of bolt holes. At this time, check that lines (A), (B), (C) and
a The pitch diameter of the bolt holes and oil (D) are in parallel.
holes is different. a Match the bolt holes by turning the gerotor
ring without separating the drive and gero-
tor star from each other.
a The above procedure is important for
aligning the valve timing.
13. Turn spool and sleeve assemblly and set pin

(12) and port surface (46) of housing in paral-
lel. Insert drive (8) into portion (47), then mate
drive yoke and pin (12). To carry out position-
ing exactly, use a felt pen to draw line on end
face of drive (8) parallel to pin.
10 HM400-2
16. Assemble spacer (5) to spline Gerotor star. 17. Order for tightening end cap mounting screws
a Do not assemble spacers to 51 cc/rev and is as shown in diagram below.
69 cc/rev discharge capacity Orbit-rolls.
Asseble 2 spacers to 184 cc/rev discharge
capacity Orbit-roll.
Assemble O-ring (22) to end cap (3), set
on top of Gerotor, then align bolt holes.
Coat 6 screws (1) and thread of retainer
screw assembly (2) with oil, then assem-
ble to end cap.
Install retainer screw assemblies to bolt
holes where adapter screws have already
been assembled. 14.7 Nm {1.5 kgm}, then
tighten in order to following torque.
a After tightening to torque given below,

install handle to spool and check that
spool rotates.
Screw tightening torque
Discharge capacity Tightening torque

(cc/rev) (Nm {kgm})
51 – 230 22.6 {2.3}
277 23.5 {2.4}
369 – 737 28.4 {2.9}
List of capacities and spacers
Discharge Discharge
Spacer
capacity capacity
thickness (mm)
symbol (cc/rev)
A 51 —
B 69 —
C 96 3.6
D 120 6.1
E 159 12.2
12.2
G 184
3.6
K 230 22.0
M 277 24.4
P 369 41.1
S 461 53.7
T 553 66.4
U 737 91.8
HM400-2 11
Removal and installation of flow 1. Drain hydraulic oil.

amplifier valve assembly 1 6 l
Hydraulic tank: 120l
Special tools 2. Remove inner cover (1) of the left fender.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Removal
3. Open up the engine hood.
k
4. Remove 4 each mounting bolts from the right
and left mounts at the front of the cab.
lock knob.
a Check the thickness, quantity, and posi-
tions of the inserted shims.
chock the wheels.
5. Sling operator's cab (32) and tilt it up.
and rear frame.
a Use 2 shackles (S) so that hook (F) of the
q Precautions in tilting cab sling will not hit glass (G) of the cab
k When tilting the cab, check that the lock assembly.
k Do not start the engine while the cab is 6. Pull lock lever (31) and set lock bar (30) with
tilted. the care the direction of the lock bar (30).
k When it is obliged to start the engine for k Check that the lock lever (31) closes
testing etc., check that there is nobody and the operator cab assembly (32) is
under the cab. held securely in position by the lock
k Do not operate the gear shift lever or dump bar (30).
lever. For details about cab tilt, see "Method of tilting
k Do not give a large shock to the machine. cab up" in chapter Testing and adjusting.
k Do not tilt the cab while it is loaded. a Pump assembly X2 is necessary for tilting

the internal pressure of the hydraulic tank.
12 HM400-2
4) Disconnect pump circuit (HP) hose (8) and

remove tank circuit (HT) piping (9).
5) Disconnect steering cylinder circuit pipes
(CL) (10) and (CR) (11) from the steering
valve and fix them.
6) Remove flow-amplifier valve (12).
4 Flow-amplifier valve: 35 kg
7. Flow-amplifier valve
1) Remove cover (2) on the top of the left
fender and cover (2a) on the left side of
the flow-amplifier valve.
2) Remove the wire harness clamp and dis-
connect the steering hose and R, P, T, L,
and LS circuit hoses (3) – (6).
Installation
removal.
3) Remove the mounting bolts of pipe (7) of

priority circuit (EF) (the circuit to the port P
of the hoist valve) and keep pipe (7) away
from the steering valve.
a Loosen the mounting bolts of port P
of the hoist valve.
HM400-2 13
Removal and installation of hoist 1. Drain the hydraulic oil.

valve assembly 1
2. Left fender
Special tools Lift off left fender (1).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Removal
and the dump body, set the steering in a 3. Open up the engine hood.
machine on the level ground. 4. Remove 4 each mounting bolts from the right
k Lock the dump lever with the dump lever and left mounts at the front of the cab.
lock knob. a Check the thickness, quantity, and posi-
k Turn the parking brake switch ON and tions of the inserted shims.
chock the wheels.
k Set the lock bar to the frame and lock front 5. Sling operator's cab (32) and tilt it up.
and rear frame. a Use 2 shackles (S) so that hook (F) of the
sling will not hit glass (G) of the cab
assembly.
6. Pull lock lever (31) and set lock bar (30) with
the care the direction of the lock bar (30).
k Check that the lock lever (31) closes
tilted.
and the operator cab assembly (32) is
held securely in position by the lock
under the cab.
bar (30).
For details about cab tilt, see "Method of tilting
lever.
cab up" in chapter Testing and adjusting.
a Pump assembly X2 is necessary for tilting

k Check that the body is lowered completely.
the internal pressure of the hydraulic tank.
14 HM400-2
3) Disconnect hoses (7) and (8) of pilot ports

(PA) and (PB).
4) Remove check valve (9). [*1]
5) Disconnect tube (10) and (11) of hoist cyl-
inder ports (A) and (B).
a Loosen the rear tube clamp and move
the tubes toward the hydraulic tank.
7. Flow-amplifier valve
Remove the flow-amplifier valve assembly. For
details, see "Removal and installation of flow-
amplifier valve assembly".
8. Hoses and piping

1) Disconnect port P tube of the hoist valve
and tank circuit hoses (2), (3) and (4). 9. Hoist valve
2) Remove bracket (5) and tank circuit tube Remove hoist valve assembly (12).
(6). 4 Hoist valve assembly: 65 kg
a Remove the throttle between tube (6)
and hoist valve, too.
Installation
removal.
[*1]
3 Check valve mounting bolt
Thread 12 mm in diameter:
98 – 123 Nm {10 – 12.5 kgm}
Refilling with oil

q Add specified oil to the specified level.
HM400-2 15
Disassembly and assembly of hoist valve assembly 1

Disassembly
1. Housing assembly 3. Body assembly

1) Remove housing (2) from body (1). 1) Remove spool (30) and plug (31) from
2) Loosen nut (3). body (1).
3) Remove screw (4), spacer (5), spring (6) 2) Remove seat (32), spring (33) and valve
and puppet (7). (34) from body (1).
4) Remove plug (8).
5) Loosen sleeve (9) and remove spring (10),
seat (11), piston (12), spring (13), seal
(14), puppet (15), sleeve (16) and orifice
(17).
2. Spring case assembly

1) Remove spring case (18) from body (1)
and then remove springs (19) and (20)
and retainer (21).
2) Remove spring case (22) from body (1)
and then remove retainer (23).
3) Remove plug (24).
4) Remove flange (25) from spring case (22),
then r emo ve s pri ngs (26 ) and ( 27) ,
retainer (28) and spring (29).
16 HM400-2
Assembly
q Clean all the parts carefully and remove burrs. 3. Housing assembly
q Apply engine oil to the sliding parts before 1) Install orifice (17), sleeve (16), puppet
installing. (15), seal (14), spring (13), piston (12),
seat (11) and spring (10) to housing (2)
1. Body assembly and tighten sleeve (9).
1) Install valve (34), spring (33) and seat (32) 2) Tighten plug (8).
to body (1). 3) Install puppet (7), spring (6) and spacer
2) Install plug (31) and spool (30) to body (1). (5) and tighten screw (4) and nut (3).
4) Install housing (2) to body (1).
2. Spring case assembly 2 Mating faces of housing and body:
1) Install spring (29), retainer (28) and Sealant (LOCTITE #572 or 575
springs (27) and (26) to spring case (22) or Sealend #242)
and then install flange (25). 3 Housing
2) Install plug (24). Thread 12 mm in diameter:
3) Install retainer (23) to body (1) and then 98 – 123 Nm {10 – 12.5 kgm}
install spring case (22). Thread 14 mm in diameter:
4) Install retainer (21) and springs (20) and 157 – 196 Nm {16 – 20 kgm}
(19) to body (1) and then install spring
case (18).
HM400-2 17
Disassembly and assembly of Disassembly

steering cylinder assembly 1 1. Piston rod assembly
1) Remove the piping from the cylinder assem-
Special tools bly.
2) Remove mounting bolts (1a) and seal
New/Remodel
cage assembly (1).
Necessity
Sym-
Part No. Part name 3) Remove check valve (1b).
Sketch
bol
a Put an oil pan etc. under the cylinder to
Q'ty
receive the oil.
Cylinder repair
790-502-1003 t 1
1 stand
3
790-102-4310 Pin t 2
790-720-1000 Expander t 1
4 796-720-1670 Ring t 1
07281-01279 Clamp t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1 4) Set cylinder assembly (2) to tool U1.
U
• Push tool 5) Loosen the cylinder head nut and remove
5
(Outside diame- cylinder head assembly (3) with tool U2.
ter: 135 mm,
790-201-1811 1
Inside diameter:
130 mm, Length:
35 mm)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 • Plate
(Outside diameter
790-201-1620 of dust seal press 1
fitting part: 146
mm)
6) Pull out and remove cylinder head and

piston rod assembly (4) from cylinder (5).
a When the piston rod assembly is
pulled out from the cylinder, oil will
come out, so catch it in a container.
7) Remove cylinder (5) from tool U1.
18 HM400-2
8) Disassemble the piston rod assembly 3] Using tool U3, remove piston assem-
according to the following procedure. bly (6).
1] Set piston rod assembly (4) to tool q When not using tool U3, loosen
U1. the piston assembly by using the
drilled holes (DH) (ø10: 2 places).
2] Remove piston assembly lock screw

(5). 4] Remove head assembly (7).
Screw size: M12, P = 1.75 mm 5] Remove seal cage (8).
6] Remove plate (8a).
a If screw (5) is so caulked that you

cannot remove it, tighten it tempo- 7] Remove cap (9), 9 balls (10) and
rarily and cut the threads on it with tap plunger (11).
[1], and then remove it.
HM400-2 19
2. Disassembly of piston assembly Assembly

1) Remove wear rings (12).
2) Remove piston ring (13). a Take care not to damage the packings, dust
3) Remove the O-ring and backup ring (14). seals, O-rings, etc.
a Clean all the parts. After installing them, cover
the piping ports and pin holes to prevent dirt
from entering.
a Do not insert each backup ring forcibly, but
warm it in water at 50 – 60 °C and then insert
it.
a Clean all the parts and check them for dirt or
damage. Coat their sliding surfaces with
1. Assembly of seal cage

1) Install seal ring (21).
2) Install ring (20).
3. Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (15).
2) Remove O-ring (16)
3) Remove rod packing (17).
5) Remove dust seal (19).
2. Assembly of head assembly

1) Using tool U5, press fit bushing (18).
2) Install rod packing (17).
3) Using tool U6, press fit dust seal (19).
4) Install O-ring (16).
5) Install backup ring and O-ring (15).
4. Disassembly of seal cage assembly

1) Remove ring (20).
20 HM400-2
4. Piston rod assembly

1) Set piston rod assembly (2) to tool U1.
3. Assembly of piston assembly

1) Using tool U4, expand piston ring (13).
a Set the piston ring to tool U4 and give 2) Set plunger (11) to the piston rod. Install 9
the handle 8 – 10 turns to expand the balls (10) and secure them with cap (9).
piston ring. a Check that there is some play at the
2) Set tool U4 and contract piston ring (13). plunger end.
3)Install backup ring and O-ring (14). 3) Install plate (8a).

4)Install wear ring (12). 4) Install seal cage (8).
5) Install head assembly (7).
a Do not increase the closed gap of the
ring too much.
2 Ring groove: Grease (G2-LI)
HM400-2 21
6) Assemble piston assembly (6) according 3] After making the hole, remove all the
to the following procedure. chips and dirt and clean thoroughly.
q Perform this work when reusing pis-
ton rod assembly (2) and piston
assembly (6).
a Clean the parts thoroughly to remove
metal chips and dirt.
1] Tighten piston assembly (6). Then,
using tool U3, tighten piston assem-
bly (6) until screw holes (H) are
aligned.
a Remove the burrs from the
threads with a file.
4] Tighten screw (5).

2 Threaded part (b) of screw:
Adhesive (LT-2)
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
5] Caulk 4 points (a) of the threaded part
with a punch.
q When replacing either or both of the

rod and piston
1] Screw in piston assembly (6) until it
touches rod end [B] and then tighten
it to the specified torque with tool U4.
2] Make 1 screw hole to install the screw.

a Make 1 hole horizontally with a
d r i l l a t t h e V- g r o o v e o f t h e
threaded part of piston (6) and
rod (3).
q Threading dimensions (mm)
Diameter Depth of
Tap to be Tapping
of tap drill tap drill
used depth
hole hole
10.3 27 12 x 1.75 20
22 HM400-2
7) Remove piston rod assembly (2) form tool 4) Install seal cage (1) and tighten bolts (1a).
U1. 5) Install check valve (1b).
3 Check valve:
83.4 – 147 Nm {8.5 – 15 kgm}
5. Piston rod assembly

1) Set cylinder (5) to tool U1.
2) Install cylinder head and piston rod
assembly (4) to cylinder (5).
3) Using tool U2, tighten cylinder head assem-
bly (3).
3 Cylinder head nut:
932 ± 93 Nm {95 ± 9.5 kgm}
HM400-2 23
Disassembly and assembly of Disassembly

hoist cylinder assembly 1 1. Set cylinder assembly (1) to tool U1.
Special tools 2. Using tool U2, loosen and remove cylinder
head assembly (1).
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Cylinder repair
790-502-1003 t 1
1 stand
3
790-102-4310 Pin t 1
790-720-1000 Expander t 1
4 796-720-1670 Ring t 1
07281-01279 Clamp t 1 3. Remove No. 2 cylinder and rod assembly (20)
790-201-1702 Push tool kit t 1 from No. 1 cylinder (2).
790-101-5021 • Grip 1
01010-50816 • Bolt 1
• Push tool
(Outside diame-
U 5 ter: 135 mm,
790-201-1811 1
Inside diameter:
130 mm, Length:
35 mm)
790-201-1881 • Push tool 1
790-201-1841 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
4. Remove snap ring (12) from No. 2 cylinder (4).
• Plate
6 (Outside diameter
790-201-1620 of dust seal press 1
fitting part: 146
mm)
790-201-1690 • Plate 1
790-201-1650 • Plate 1
24 HM400-2
5. Lift off rod (5) from No. 2 cylinder (4). 2) Using tool U3, remove piston assembly
(13).
a When not using tool U3, loosen the
piston assembly by using the drilled
holes (DH) (ø 10: 2 places).
1) Remove piston assembly lock screw (24).
6. Remove cylinder head assembly (6) from No.

2 cylinder (4).
7. Remove wear ring (7).
a If screw (24) is so caulked that you

cannot remove it, tighten it tempo-
rarily and cut the threads on it with tap
[1], and then remove it.
8. Disassembly of cylinder head assembly

1) Remove the O-ring backup ring (22), snap
ring (21), dust seal (9) and rod packing
(10).
HM400-2 25
9. Disassembly of piston assembly Assembly

Remove piston ring (14), wear ring (15), O-ring
and backup ring (23) from piston assembly a Take care not to damage the packings, dust
(13). seals, O-rings, etc.
a Clean all the parts. After installing them, cover
the piping ports and pin holes to prevent dirt
from entering.
a Do not insert each backup ring forcibly, but
warm it in water at 50 – 60 °C and then insert
it.
a Clean all the parts and check them for dirt or
damage. Coat their sliding surfaces with
1. Using tool U5, press fit bushing (19) to No. 2

cylinder (4).
10. Remove snap ring (16) from No. 2 cylinder (4)

and then remove dust seal (17), rod packing
(18) and bushing (19).
2. Install rod packing (18) to No. 2 cylinder (4).

a Check the installed direction of the rod
packing.
3. Using tool U6, press fit dust seal (17) to No. 2

cylinder (4).
26 HM400-2
4. Install snap ring (16). 6. Assembly of cylinder head assembly

5. Assembly of piston assembly

1) Using tool U4, expand piston ring (14) and 2) Install rod packing (10) to cylinder head
install it to piston (13). (6).
a Set the piston ring to the tool and give a Check the installed direction of the
the handle 8 – 10 turns to expand the rod packing.
piston ring.
2) Set tool U4 and contract piston ring (14).
3) Install wear ring (15).
4) Install O-ring and backup ring (23).
HM400-2 27
3) Using tool U6, install dust seal (9). 2) Install rod packing (18).
5) Install O-ring and backup ring (22).
6) Install rod packing (10).
3) Using tool U6, install dust seal (17).
7. Assembly of No. 2 cylinder assembly

28 HM400-2
8. Install cylinder head (6) to No. 2 cylinder (4). 2) Make 1 screw hole to install the screw.
a Make 1 hole horizontally with a drill at
9. Install wear ring (7). the V-groove of the threaded part of
piston (13) and rod (5).
q Threading dimensions (mm)
Diameter of Depth of Tap to be Tapping
tap drill hole tap drill hole used depth
10.3 27 12 x 1.75 20
3) After making the hole, remove all the chips

and dirt and clean thoroughly.
10. Assemble piston assembly (13) according to

q When reusing piston rod assembly (5) and
piston assembly (6)
a Clean the parts thoroughly and remove
metal chips and dust.
1) Using tool U3, tighten piston assembly
(13) until the screw holes (H) are aligned.
a Remove burrs and fins from the
threads with a file etc. 4) Tighten screw (24).
2 Threaded part of screw:
Adhesive (LT-2)
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
5) Caulk 4 points of the threaded part with
punch (a).
q When replacing either or both of the rod

and piston
1) Screw in piston assembly (13) until it
touches rod end [B] and then tighten it
with tool U4 to the specified torque.
HM400-2 29
11. Sling rod (5) and install it to No. 2 cylinder (4). 14. Install cylinder head (1) to No. 1 cylinder (2) and
tighten it with tool U2.
3 Cylinder head:
1.25 ± 0.13 kNm {128 ± 12.8 kgm}
12. Install snap ring (12) to No. 2 cylinder (4).
13. Install No. 2 cylinder and rod assembly (20) to

No. 1 cylinder (2).
30 HM400-2
HM400-2 31

© 2008 KOMATSU
All Rights Reserved
32 HM400-2
SEN01449-02
HM400-2

HM400-2 2001 and up

Cab and its attachments
Removal and installation of operator's cab ..................................................................................................... 2
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 7
Disassembly and assembly of operator’s seat assembly ............................................................................. 13
Removal and installation of air conditioner unit assembly ............................................................................ 23
HM400-2 1
Removal and installation of k In the case that you do not drain the cool-
operator's cab 1 ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
Special tools high, you may be scalded. In this case,
New/Remodel
and then disconnect the heater hose.
Sym-
Necessity
Part No. Part name
bol 1. Open engine hood (1).
Sketch
Q'ty
X4 792-454-1100 Pump assembly q 1 N
Removal
lock knob.
k Turn the parking brake switch ON and 2. Remove 4 each mounting bolts from the right
chock the wheels. and left mounts at the front of the cab.
k Set the lock bar to the frame and lock front a Check the thickness, quantity, and positions
and rear frame. of the inserted shims.
k When tilting the cab, check that the lock 3. Sling operator's cab (3) and tilt it up.
lever is fixed securely. a Use 2 shackles (S) so that hook (F) of the
k Do not start the engine while the cab is sling will not hit glass (G) of the cab assem-
tilted. bly.
testing etc., check that there is nobody 4. Pull lock lever (2-1) and set lock bar (2) with the
under the cab. care the direction of the lock bar (2).
k Check that the lock lever (2-1) closes
lever. and the operator cab assembly (3) is
k Do not give a large shock to the machine. held securely in position by the lock bar
k Do not tilt the cab while it is loaded. (2).
For details about cab tilt, see "Method of tilting
cab up" in chapter Testing and adjusting.
k Disconnect the cable from the negative (–) a Pump assembly X4 is necessary for tilting
terminal of the battery. up by tilt cylinder.
k Collect the air conditioner refrigerant
(R134a) from air conditioner circuit in
advance.
a Ask professional traders for collecting and filling
operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must
be conducted by a qualified person.
2 HM400-2
6. Disconnect air conditioner hoses (10). [*1]

a Stop the openings with tapes, etc. to pre-
vent air from entering them
7. Disconnect heater hoses (11).

a Prepare an oil container.
8. Disconnect hoses (12) from steering valve

(SV).
a Underview of operator's cab.
9. Disconnect connectors (13) – (20).

• (13): J08, (14): J01
• (15): J09, (16): J02
• (17): J03, (18): J05
• (19): J04, (20): J06
5. Disconnect hoses (5) – (9) from brake valve

(BV).
• (5), (6): Port PA and PB
• (7): Port T
• (8): Port B
• (9): Port A
• (SV): Steering valve
a Check the destination of each hose.
a Prepare an oil container.
a Put plugs to the hoses.
a When disconnecting the hose from brake
valve (BV), make a matchmark at the posi-
tion of the hose clamp and take care that
noise will not be increased by the sag of the
hose.
HM400-2 3
10. Disconnect ground terminal (22). 2) Remove cover (31)

a Disconnect connector PWR from inside
11. Fix cylinder (24) temporarily to prevent it from of the cover.
falling down and remove pin (23). 3) Remove cover (32).
a Retract cylinder (24).
a Check the thickness, quantity, and positions
of the inserted shims.
4) Remove covers (33) and (34).
12. Return the operator's cab assembly (3) to the

horizontal position.
13. Disconnect rearview monitor cable (21) in the

following steps.
5) Remove storage box (35).

6) Remove cover (36).
7) Remove clamp (37) from rear view monitor
cable (21).
1) Remove seat (30).
4 HM400-2
8) Remove the external air filter cover (38) 14. Sling the operator's cab assembly temporarily
from outside of the operator's cab and by using plate (P).
remove the external air filter.
9) Remove external air filter box (39).
15. Remove pin (25).[*3]

a Check the thickness, quantity, and positions
10) Remove the rear mounting bolts and of the inserted shims.
remove cover (40) from the dashboard.
16. Lift off operator's cab assembly (3).

11) Disconnect band (41).
4 Operator's cab assembly: 1,200 kg
12) Disconnect connector (42) from monitor
(M).
13) Remove the molding material of grommet
(G). [*2]
14) Drop monitor cable (21) below the opera-
tor's cab.
HM400-2 5
Installation [*3]
a Adjust the shims so that the clearance
• Carry out installation in the reverse order to between operator's cab (3) and mount (26)
removal. will be (a) on each side.
• Standard clearance (a): 0.2 mm (Each side)
[*1] • Kinds of shim thickness:
a When installing the air conditioner circuit 0.5 mm, 1.0 mm, 2.3 mm
hoses, take care that dirt and water will not
enter them.
a When installing each air conditioner hose,
check that the O-ring is fitted to the joint.
a Check each O-ring for a flaw and deteriora-
tion.
a When connecting the refrigerant piping,
coat the O-rings with compressor oil for
new refrigerant R134a (DENSO: ND-OIL 8,
ZEXEL: ZXL 100 PG (equivalent to PAG
46).
3 Tightening torque for air conditioner pip-
ing
Thread size Tightening torque
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm} • Filling air conditioner circuit with refrigerant
22 x 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm} (R134a)
Fill the air conditioner circuit with refrigerant
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
(R134a).
a Quantity of refrigerant: 1,200 ± 50 g
[*2]
Make seal the grommet (G) area of the monitor • Refilling with coolant
cable. Add coolant through the coolant filler to the
2 Oblique line area in the grommet (G)
specified level. Run the engine to circulate the
(100% full): coolant through the system. Then, check the
CEMEDINE 366E or equivalent coolant level again.
6 HM400-2
Removal and installation of Procedure

operator's cab glass (Stuck glass)1 Preparation (Cleaning)
O
a Among the panes of window glass on the 4 Applying primer
sides of the operator's cab, 5 panes (1) – (5)
• Cab side: SUNSTAR 435-95
shown in the figure are stuck.
• Glass side: SUNSTAR 435-40
a In this section, the procedure for replacing the
stuck glass is explained. O Dry for at least 5 minutes and stick within
(1) Front window glass 24 hours.
(2) Left rear window glass Sticking both-sided adhesive tape (cab side)
(3) Rear window glass O
(4) Right rear window glass Positioning window glass
(5) Right door sash assembly (Sash is stuck) O
Applying adhesive (SUNSTAR Industrial sealant,
Petaseal 551) (cab side)
O Within 5 minutes
Sticking window glass
* Keep pressing the glass for at least 10 hours.
HM400-2 7
Special tools a If the window glass is broken finely, it may

be removed with knife [4] and a screw-
New/Remodel
driver.
Sym- a Widening the cut with a flat-head screw-
Necessity
Part No. Part name
bol
Sketch
driver, cut the adhesive and both-sided
Q'ty
adhesive tape with knife [4].
2 793-498-1210 Lifter t 2
X (Suction cup) (The following figure shows the operator's cab
3 20Y-54-13180 Stopper rubber t 2 of a wheel loader.)
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator's cab
(metal sheet) (8).
2. Remove the window glass.
a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with pliers [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the fric-
tional heat, apply lubricant to it.
(The following figure shows the operator's cab

of a wheel loader.)
8 HM400-2
Installation Applying primer

3. Apply primer (10).
Preparation a The using limit of the primer is 4 months
1. Using a knife and scraper [5], remove the after the date of manufacture. Do not use
remaining adhesive and both-sided adhesive the primer after this limit.
tape from the metal sheets (glass sticking sur- a Use the primer within 2 hours after unpack-
faces) of the operator's cab. ing it.
a Remove the adhesive and both-sided adhe- a Even if the primer is packed again just after
sive tape to a degree that they will not affect it is unpacked, use it within 24 hours after it
adhesion of the new adhesive. Take care is unpacked for the first time. (Discard the
not to scratch the painted surfaces. (If the primer 24 hours after it is unpacked.)
painted surfaces are scratched, adhesion 1) Stir both of the paint primers and glass
will be lowered.) primer sufficiently before using them.
a If the primer has been stored in a refrig-
(The following figure shows the operator's cab erator, leave it at the room temperature
of a wheel loader.) for at least half a day before stirring it.
(If the primer is unpacked just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
2. Remove oil, dust, dirt, etc. from the sticking sur-

faces of cab (8) and window glass (9) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them in air for at least 5 minutes to dry.
(The following figure shows the operator's cab
of a wheel loader.)
HM400-2 9
3) Evenly apply paint primer to the surfaces to 4) Evenly apply glass primer all around inside
stick both-sided adhesive tapes. of the black coated surface of window glass
(a): Min. 30 mm (9).
2 Primer for cab (painted surface): (a): Min. 30 mm
SUNSTAR 435-95 2 Glass primer: SUNSTAR 435-40
a Do not apply the primer more than 2 a The black coating is for prevention of
times. (If it is applied more than 2 deterioration by light.
times, its performance will be lowered.) a Do not apply the primer more than 2
a Never apply wrong primer. If you have times. (If it is applied more than 2
applied the glass primer, etc. by mis- times, its performance will be lowered.)
take, wipe it off with white gasoline.
a After applying the primer, leave it for at
least 5 minutes in air to dry and stick
the both-sided adhesive tape within 24
hours.
(The figure shows the operator's cab of
a hydraulic excavator.)
a (8): Cab
a (9): Glass
a Never apply wrong primer. If you have

applied the paint primer, etc. by mis-
take, wipe it off with white gasoline.
10 HM400-2
Sticking both-sided adhesive tape a (8): Cab

4. Stick both-sided adhesive tape (6) along the a (a): Range to apply primer (Described
edge of cab (8). above)
a Do not remove the release tape of the both- a (15): Adhesive (Described below)
sided adhesive tape on the glass sticking
side before sticking the glass.
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window
frame.
Positioning window glass

5. Position the new window glass.
1) Check the clearance between the window
glass and the operator's cab on the right,
left, upper, and lower sides, and then adjust
it evenly.
2) Stick tapes [6] between window glass (9)
a When sticking both-sided adhesive tape (6) and operator's cab (8) and draw positioning
around a frame, do not lap its finishing end line (n).
over the starting end but make clearance a Stick tapes [6] to the right, left, and
(e) of about 5 mm between them. lower parts of the glass for accurate
1) Stick both-sided adhesive tape (6) for right positioning.
window glass (1) as shown in the figure. 3) Cut the tape between window glass (9) and
a (The figure shows the operator's cab of operator's cab (8) with a knife, and then
a hydraulic excavator.) remove the window glass.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
(The figure shows the operator's cab of a
hydraulic excavator.)
HM400-2 11
Applying adhesive 7. Apply the adhesive.

6. Prepare for applying the adhesive. a Apply adhesive (15) to dimensions (s) and
• Adhesive: (t) of both-sided adhesive tape (6) of opera-
SUNSTAR Industrial sealant, Petaseal tor's cab (8).
551 • Dimension (s): 10 mm
a The using limit of the adhesive is 4 months • Dimension (t): 15 mm
after the date of manufacture. Do not use 2 Adhesive: SUNSTAR Industrial seal-
the adhesive after this limit. ant, Petaseal 551
a Keep the adhesive in a dark place where a Apply adhesive (15) higher than both-sided
the temperature is below 25°C. adhesive tape (6).
a Never heat the adhesive higher than 30°C. a Apply the adhesive evenly.
a When reusing the adhesive, remove the all a (a): Range to apply primer (Described
hardened part from the nozzle tip. above)
a Stick the glass within 5 minutes after apply-
1) Set adhesive cartridge (12) to caulking gun ing the adhesive.
[7].
a An electric caulking gun is more effi-
cient.
2) Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as fol-
lows.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
3) Remove the release tape of the both-sided

adhesive tape on the glass side.
12 HM400-2
Disassembly and assembly of operator’s seat assembly 1

a The procedure for disassembling and assembling the operator's seat assembly [with air suspension
(manufactured by ISRING HAUSEN)] is shown below.
a This operator's seat is if equipped.
A: Headrest E: Left-hand armrest

B: Seatback F: Suspension cover
C: Seat cushion G: Sliderails
D: Right-hand armrest
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of the 2 clips (2) of headrest stay (1) on
both sides.
HM400-2 13
2) Apply force (b) to part (a) of each clip (2) 2. Seatback

in the direction of the arrow to turn the clip. 1) Disconnect 3 air hoses (5) from the rear
Release headrest stay (1) from part (d) of left of seatback (4).
the clip and pull out up headrest (3). a Before disconnecting the air hoses,
check their types.
2) Remove seatback hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simulta-

neously, remove headrest (3).
3) Bring seatback (4) down forward.
14 HM400-2
4) Apply force (E) to the right side of seat- 2) Push cushion stopper wire (9) down with
back (4) in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and
right side up. remove it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion q The procedure for disassembling right-
1) Push cushion adjuster lever (7) inward hand armrest (10) is shown below.
and slide seat cushion (8) to the front end. (Disassemble left-hand armrest (11) simi-
larly.)
HM400-2 15
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment wash-
a Use a flat-head screwdriver, etc. to ers (16) installed to each bolt between
remove the cap. the armrest and seatback. Take care
2) Loosen armrest hinge mounting bolt (13). not lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of 1) Remove right-hand hinge cover (17).
right-hand armrest (10). 2) Remove plastic plate (18) from the rear
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
4) Turn right-hand armrest (10) up by 180 °.

a If the armrest is not turned, you can-
not apply the tool to upper mounting
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B).
16 HM400-2
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part;2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
4) Remove 4 mounting bolts (20), cushion

rear fixing plate (21), 2 cushion rails (22),
and 4 bushings (23).
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
5) Remove 3 metallic suspension cover clips

(24).
HM400-2 17
2) Slide rails (28) to the rear end. Assembly

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part 1. Rails
of each rail. 1) Put height adjustment washers (31)
between rails (28) and suspension, and
then set rails (28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part 2) Set rails (28) to the front end and install 1
of each rail, and then remove rails (28). lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjust-

ment washers (31) between the rails
and suspension.
18 HM400-2
3) Set rails (28) to the rear end and install 1 2) Install 3 metallic suspension cover clips
lock washer (30) and 1 hexagon socket (24).
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
3) Set 4 bushings (23) and 2 cushion rails

(22), and then install cushion rear fixing
plate (21), and 4 mounting bolts (20).
2. Suspension cover 3 Cushion rail mounting bolt:
1) Set suspension cover (27) in position and 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
install 6 plastic suspension cover clips
(small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part;2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings (19).
HM400-2 19
5) Install plastic plate (18) to the rear. 2) Tighten lower mounting bolt (15A) lightly
6) Install right-hand hinge cover (17). and turn armrest (10) by 180°.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
3. Armrest
q The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) simi-
larly.)
6) Tighten armrest hinge mounting bolt (13).

a Tighten the bolt so that the arm will
move smoothly.
q Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16)

for each bolt and set right-hand armrest
(10) in position.
20 HM400-2
4. Seat cushion 5. Seatback

Slide in the seat cushion from the front of the 1) Insert the left side of seatback (4), and
fitting position. then lower and set the right side.
a If seat cushion (8) is slid to the rear, it
is locked by cushion stopper wire (9).
2) Install seatback hinge mounting bolt (6)

(M8 bolt).
3 Seatback hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
HM400-2 21
3) Connect 3 air hoses (5) to the rear left of

the seatback (4).
6. Headrest
Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides
are locked securely.
22 HM400-2
Removal and installation of air 2) Tilt up operator's cab (3).

conditioner unit assembly 1 a Using 2 shackles (S), arrange sling
hook (F) so that it will not hit glass (G)
Special tools of the cab assembly.
k Check that lock (2) is applied
New/Remodel
securely.
a Keep slinging operator's cab (3) (tem-
Necessity
Sym-
Part No. Part name
porarily).
Sketch
bol
Q'ty
799-703-1200 Service tool kit t 1
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 1 799-703-1111 t 1
(220V)
Vacuum pump
799-703-1121 t 1
(240V)
799-703-1401 Gas leak detecter t 1
Removal
k Stop the machine on a level ground, apply 2. Heater hose
the parking brake, and then lock the tires 1) Disconnect heater hose (4).
with chocks. a Check the connecting parts of the
k Set the lock bar to the frame. heater hose.
k Disconnect the cable from the negative (–) a Prepare an oil receiver.
terminal of the battery. 2) Remove covers (5) and (6).
k If the radiator coolant temperature is high,
wait until it lowers to avoid scalding your-
self before disconnecting the heater hose.
k Collect the air conditioner refrigerant
(R134a) in advance.
k If refrigerant (R134a) gets in your eyes, you
may lose your sight. Accordingly, when
collecting or adding it, you must be quali-
fied for handling the refrigerant and put on
protective goggles.
1. Operator's cab and engine hood

securely. 3) Disconnect drain hose clamps (7) and (8).
HM400-2 23
3. Return the operator's cab tilted up to the hori- 8. Remove frame (13).
zontal position.
4. Remove navigator's seat (9).
9. Remove relay plate assembly (14) and move it

to this side.
5. Remove right pillar cover (10).
6. Remove cover (11) under the navigator's seat.
10. Remove the 4 mounting bolts and retarder

controller (15).
7. Remove seat rear cover (12).
24 HM400-2
11. Disconnect connectors BRC1 (16), BRC2 (17) 14. Remove controller mounting frame (23).
and BRC3 (18) from retarder controller (15).
15. Remove center console (24).

12. Remove the 4 mounting bolts and transmission
controller (19). 16. Remove upper plate (25).
13. Disconnect connectors ATC1 (20), ATC2 (21) 17. Remove duct (26).
and ATC3 (22) from transmission controller
(19).
HM400-2 25
18. Remove duct (27). 23. Remove external air filter box (34).
19. Disconnect hose (28). 24. Remove rear mounting bolts (35) and (36) of
air conditioner unit assembly (37).
20. Remove mounting bolt (29) and disconnect
hose assembly (30).
21. Remove mounting bolt (31) and disconnect air

conditioner hose assembly (32). [*1]
a Cover the hose end with a tape etc. to
seal it from the outside air.
a Take care that the O-ring of the hose
adapter will not fall.
22. Remove external air filter cover (33) from the

outside of the operator's cab.
a Remove the air conditioner unit assembly
mounting bolts (rear 4 bolts) through this
opening.
26 HM400-2
25. Remove front mounting bolts (38). While lifting Installation

up air conditioner unit assembly (37), pull it
out. q Carry out installation in the reverse order to
removal.
26. After air conditioner unit assembly (37) is
pulled out halfway, disconnect the following. [*1]
q Connector AC1 (39) a When installing the air conditioner circuit
a Disconnect the wiring harness clamp, too. hoses, take care that dirt, dust, water, etc. will
q Drain hose (40) from bottom not enter them.
a When connecting each air conditioner hose,
check that the O-rings are fitted to its joints.
a Check that each O-ring is not damaged or
deteriorated.
a When connecting the refrigerant hoses, apply
compressor oil for new refrigerant (R134a)
( DEN SO : ND- O IL8, ZE XE L: ZXL 100 PG
(equivalent to PAG46)) to their O-rings.
3 Air conditioner hose assembly mounting bolt:
8 – 12 Nm {0.8 – 1.2 kgm}
Charging air conditioner with refrigerant gas

q Using tool X1, charge the air conditioner circuit
with refrigerant (R134a).
a Quantity of refrigerant: 1,200 ± 50 g

q Add coolant up to the specified level. Run the
engine to circulate the coolant through the sys-
tem. Then, check the coolant level again.
HM400-2 27

© 2009 KOMATSU
All Rights Reserved
28 HM400-2
SEN01450-02
HM400-2

HM400-2 2001 and up

Electrical system
Removal and installation of retarder controller assembly ............................................................................... 2
Removal and installation of transmission controller assembly........................................................................ 4
Removal and installation of engine controller assembly ................................................................................. 6
HM400-2 1
Removal and installation of 5. Remove frame (5).

retarder controller assembly 1
Removal
k Stop the machine on a level ground, apply
the parking brake, and then lock the tires
with chocks.

to this side.

7. Remove the 4 mounting bolts and retarder

controller (7).
a The device on the right is the transmission
controller.
2 HM400-2
8. Disconnect connectors BRC1 (8), BRC2 (9)

and BRC3 (10) from retarder controller.
Installation
removal.
HM400-2 3
Removal and installation of 5. Remove frame (5).

transmission controller
assembly 1
Removal
k Stop the machine on a level ground, apply
the parking brake, and then lock the tires
with chocks.

to this side.

7. Remove the 4 mounting bolts and transmission
controller (7).
a The device on the left is the retarder con-
troller.
4 HM400-2
8. Disconnect connectors ATC1 (8), ATC2 (9)

and ATC3 (10) from transmission controller (7).
Installation
removal.
HM400-2 5

engine controller assembly 1
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
Removal
k
cab assembly.
k
under the cab.
lever.

6 HM400-2
2. Remove power train filter (3) from crossbar (4).
3. Remove connector (5) from engine controller

(6).
4. Remove engine controller (6).
Installation
removal.
HM400-2 7

© 2009 KOMATSU
All Rights Reserved
8 HM400-2
SEN00533-02
HM400-2

HM400-2 2001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Power train hydraulic circuit diagram .............................................................................................................. 3
Steering and hoist hydraulic circuit diagram ................................................................................................... 5
Brake hydraulic circuit diagram....................................................................................................................... 7
Brake cooling hydraulic circuit diagram .......................................................................................................... 8
Differential lock hydraulic circuit diagram........................................................................................................ 9
HM400-2 1
SEN00533-02 90 Diagrams and drawings
2 HM400-2
Power train hydraulic circuit diagram Power train hydraulic circuit diagram
HM400-2
HM400-2 3
Steering and hoist hydraulic circuit diagram 1

Serial No.: 2001 – 2603
HM400-2 5
6 HM400-2
Brake hydraulic circuit diagram 1
HM400-2 7
Brake cooling hydraulic circuit diagram 1
8 HM400-2
Differential lock hydraulic circuit diagram 1
HM400-2 9

© 2009 KOMATSU
All Rights Reserved
10 HM400-2
SEN00534-04
HM400-2

HM400-2 2001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram for inside cab (1/4) .................................................................................................. 3
Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188 ........................................................... 5
Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up ........................................................... 7
Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188 ........................................................... 9
Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up ..........................................................11
Electrical circuit diagram for inside cab (4/4) ................................................................................................ 13
Electrical circuit diagram for outside cab (1/3) .............................................................................................. 15
Electrical circuit diagram for payload meter .................................................................................................. 21
Connectors table and arrangement drawing................................................................................................. 23
HM400-2 1
2 HM400-2
Electrical circuit diagram for inside cab (1/4) Electrical circuit diagram for inside cab (1/4) 1
HM400-2
SEN00534-04
HM400-2 3
Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188 Electrical circuit diagram for inside cab (2/4) Serial No.: 2001 – 2188 1
HM400-2
SEN00534-04
HM400-2 5
Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up Electrical circuit diagram for inside cab (2/4) Serial No.: 2189 and up 1
HM400-2
SEN00534-04
HM400-2 7
Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188 Electrical circuit diagram for inside cab (3/4) Serial No.: 2001 – 2188 1
HM400-2
SEN00534-04
HM400-2 9
Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up Electrical circuit diagram for inside cab (3/4) Serial No.: 2189 and up 1
HM400-2
SEN00534-04
HM400-2 11
Electrical circuit diagram for inside cab (4/4) Electrical circuit diagram for inside cab (4/4) 1
HM400-2
SEN00534-04
HM400-2 13
Electrical circuit diagram for outside cab (1/3) Electrical circuit diagram for outside cab (1/3) 1
HM400-2
SEN00534-04
HM400-2 15
HM400-2
SEN00534-04
HM400-2 17
HM400-2
SEN00534-04
HM400-2 19
Electrical circuit diagram for payload meter Electrical circuit diagram for payload meter 1
HM400-2
SEN00534-04
HM400-2 21
Connectors table and arrangement drawing
Connectors table and arrangement drawing HM400-2 HM400-2
Connector No. Type of Number Location Address Connector No. Type of Number Location Address Connector No. Type of Number Location Address Connector No. Type of Number Location Address
connector of pins connector of pins connector of pins connector of pins
50 Terminal 1 Battery relay L-1 CH1 M 8 Machine monitor mode selector switch 1 O-2 EGR DT 2 EGR valve solenoid AC-6 R04 Relay 6 Brake lamp relay Z-1
53 Terminal 1 Battery relay K-1 CH2 M 8 Machine monitor mode selector switch 2 O-2 ENG — 60 Engine controller AH-4 R05 Relay 6 Backup lamp and buzzer relay Z-1
54 Terminal 2 Emergency steering relay L-3 CHK1 X 1 KOMTRAX set switch 1 R-7 ER Terminal 3 Chassis ground (battery room) E-1 R06 Relay 6 Fog lamp relay (if equipped) Z-2
55 Terminal 1 Emergency steering relay M-3 CHK2 X 1 KOMTRAX set switch 2 Q-7 ER Terminal 1 Chassis ground (front frame) F-1,H-2,I-3 R07 Relay 5 Auto preheat relay Z-2
56 Terminal 1 Emergency steering relay M-3 CJA DT2 6 Joint connector ER Terminal 1 Chassis ground (rear frame) M-5 R08 Relay 5 Yellow rotary lamp relay (if equipped) Z-2
57 Terminal 2 Emergency steering relay M-3 CJB DT2 8 Joint connector B-8 ER1 Terminal 1 Chassis ground (in cab) E-8 R09 Relay 6 Working lamp (front) relay Z-1
58 Terminal 2 Emergency steering relay K-2 CJE DT2 8 Joint connector A-8 ER1 Terminal 1 Chassis ground (rear frame) G-9 R10 Relay 5 Horn relay Z-1
59 Terminal 1 Emergency steering relay K-2 CJE4 DT2B 6 Joint connector AG-3 ER2 Terminal 1 Chassis ground (in cab) Z-7 R11 Relay 6 Side lamp relay (if equipped) Z-2
60 Terminal 1 Emergency steering relay K-2 CJF DT2 8 Joint connector B-9 ER3 Terminal 1 Chassis ground (in cab) Q-2 R12 Relay 6 Hazard relay 1 Z-2
61 Terminal 2 Emergency steering relay M-3 CJG DT2 8 Joint connector B-8 FE1 DT2 2 Transmission differential speed sensor I-2 R13 Relay 5 Hazard relay 2 Z-1
62 Terminal 1 Circuit breaker (80 A) N-2 CJK DT2 6 Joint connector M-8 FLS 4 Flasher V-1 R14 Relay 5 Headlamp relay Z-1
63 Terminal 1 Circuit breaker (80 A) N-2 CJL DT2 8 Joint connector N-2 FOG M 6 Fog lamp (if equipped) P-1 R15 Relay 5 Headlamp selector relay Z-1
64 Terminal 1 Circuit breaker (80 A) N-2 CJP DT2 6 Joint connector C-2 FWL 2 Front working lamp (left) F-9 R16 Relay 6 Headlamp Hi relay AA-2
65 Terminal 1 Circuit breaker (80 A) N-2 CJR DT2 8 Joint connector A-9 FWM 2 Front window washer motor (front) A-4 R17 Relay 5 Parking brake safety relay AA-2
66 Terminal 2 Battery relay K-2 CJS DT2 8 Joint connector A-8 FWR 2 Front working lamp (right) D-7 R21 Relay 5 Rear glass heater relay Z-1
69 Terminal 3 Battery relay K-2 CJT DT2 8 Joint connector A-8 G SUMITOMO 3 Engine Bkup speed sensor AE-2 R22 Relay 5 Emergency steering timer Z-1
70 Terminal 2 Emergency steering relay L-3 CJU DT2 6 Joint connector M-7 G1 Terminal 1 Chassis ground (front frame) A-3 R25 11 Power window relay Z-8
71 Terminal 2 Emergency steering relay L-3 CJY DT2 8 Joint connector A-3 GS Terminal 2 Chassis ground (engine) AH-6 R33 6 Parking brake switch W-1
72 Terminal 1 Emergency steering relay L-4 CJZ DT2 6 Joint connector M-8 HAZ 6 Hazard lamp switch R-7 R34 7 Power window switch (right) (if equipped) V-9
73 Terminal 2 Emergency steering relay L-4 CM DT2 8 Lamp/Turn signal/Dimmer switch S-1 HEAT M 6 Rear glass heater (if equipped) O-2 R35 7 Power window switch (left) V-9
74 Terminal 2 Emergency steering relay K-3 CM DT2 2 Intermediate connector E-1 HEAT1 1 Rear glass heater (if equipped) E-8 R38 Relay 5 Engine cut-off relay Z-1
75 Terminal 2 Emergency steering relay K-3 CN1 DT 2 Injector #1 AC-6 HEAT2 1 Rear glass heater (if equipped) I-9 RAD 9 Cassette radio Q-3
76 Terminal 1 Emergency steering relay K-3 CN2 DT 2 Injector #2 AD-8 HN 1 Horn switch R-2 RE1 2 Resistor S-1
77 Terminal 2 Emergency steering relay K-3 CN3 DT 2 Injector #3 AF-8 HSL DT2 4 Damper lever potentiometer Y-2 RES DT 2 Service connector AG-8
78 DT2 2 Starting motor AD-8 CN3 DT2 2 Transmission input shaft speed sensor AI-7 J01 HD 9 Intermediate connector C-8 RL 2 Room lamp E-8
80 Terminal 1 Alternator (terminal R) AC-5 CN4 DT 2 Injector #4 AG-8 J02 HD 31 Intermediate connector D-8 RL2 2 Room lamp 2 G-9
81 Terminal 1 Circuit breaker (30 A) L-1 CN4 DT2 2 Transmission intermediate shaft speed sensor AN-4 J03 HD 31 Intermediate connector C-9 RTL DT2 6 Retarder lever potentiometer S-2
82 Terminal 2 Circuit breaker (30 A) N-2 CN5 DT 2 Injector #5 AG-7 J04 HD 31 Intermediate connector D-9 RWM 2 Window washer motor (rear) A-4
83 Terminal 1 Circuit breaker (30 A) L-1 CN5 DT2 2 Transmission output shaft speed sensor AN-5 J05 HD 14 Intermediate connector D-9 SBP DT 4 Bypass valve lift sensor AE-8
84 Terminal 1 Circuit breaker (30 A) M-1 CN6 DT 2 Injector #6 AG-7 J06 DT06 4 Intermediate connector Z-5 SBS ST2 2 Seat belt switch Y-2
86 DT1 2 Intermediate connector J-3 CN6 DT2 2 Lo clutch ECMV solenoid valve AM-8 J08 HD 14 Intermediate connector C-9 SDE M 6 Side lamp switch (if equipped) P-2
94 Terminal 1 Chassis ground (rear frame) M-8 CN7 DT2 2 Lo clutch ECMV fill switch AM-8 J09 HD 31 Intermediate connector C-9 SEGR DT 4 EGR valve lift sensor AC-3
DPC3B 12 Machine monitor S-7 CN8 DT2 2 R clutch ECMV solenoid valve AM-8 J12 DT2 12 Intermediate connector J-3 SF1 DT2 12 Gearshift lever X-1
A1 1 Emergency escape switch Y-8 CN9 DT2 2 R clutch ECMV fill switch AM-8 J13 DT2 12 Intermediate connector M-6 SF2 DT2 2 Gearshift lever X-1
AC1 Air conditioner unit W-9 CN10 DT2 2 Hi clutch ECMV solenoid valve AN-7 J14 DT2 14 Intermediate connector K-4 SLL DT1 2 Side lamp (left) (if equipped) K-3
AC2 AMP 8 Air conditioner control panel P-5 CN11 DT2 2 Hi clutch ECMV fill switch AN-7 J15 DT2 14 Intermediate connector M-6 SLR 2 Side lamp (right) (if equipped) C-7
ACC 6 Retarder switch linked with accelerator Q-3 CN12 DT2 2 1st clutch ECMV solenoid valve AN-7 J18 DT2B 12 Intermediate connector F-1 SPARE X 4 Service power supply connector X-9
ACC Terminal 1 Starting switch Q-7 CN13 DT2 2 1st clutch ECMV fill switch AM-8 J19 HD 9 Intermediate connector H-2 SPL 2 Speaker (left) H-9
ACRD X 2 Air conditioner gas pressure switch C-2 CN14 DT2 2 2nd clutch ECMV solenoid valve AL-8 J1939 DT 3 Service connector AE-8 SPR 2 Speaker (right) F-8
AISS 6 AISS LOW switch Q-6 CN15 DT2 2 2nd clutch ECMV fill switch AL-9 J2P DT 50 Engine controller E-1,AH-5 ST1 Terminal 1 Emergency steering switch O-9
AS1 DT2 6 Accelerator sensor R-2 CN16 DT2 2 3rd clutch ECMV solenoid valve AL-8 J3P DT 4 Engine controller D-1,AH-3 ST2 Terminal 1 Emergency steering switch O-8
AS2 DT2 2 Accelerator sensor Serial No. 2093 and up R-2 CN17 DT2 2 3rd clutch ECMV fill switch AL-8 JCA SWP 16 Joint connector X-9 ST3 Terminal 1 Emergency steering switch O-8
ASS DT2 2 Air suspension seat Z-5 CN18 DT2 2 Lockup clutch solenoid valve AK-9 JCC SWP 16 Joint connector T-1 ST4 Terminal 1 Emergency steering switch P-9
ATC1 DRC 24 Transmission controller AB-7 CN20 DT2 2 Differential lockup solenoid valve AN-7 JCD SWP 16 Joint connector T-1 T1 Terminal 1 Chassis ground (transmission) AN-6
ATC2 DRC 40 Transmission controller AB-7 CN22 DT2 3 Torque converter intermediate oil pressure sensor AI-8 JCE SWP 16 Joint connector T-1 T01 DT2 3 Dump selector valve L-4
ATC3 DRC 40 Transmission controller AA-8 CN23 DT2 2 Torque converter oil temperature sensor AI-5 JM01 — 6 Junction wiring harness AH-5 T02 DT2 2 Dump EPC valve K-4
ATC6 X 4 Service connector Y-9 CN24 DT2 2 Transmission oil temperature sensor AI-6 JM02 — 6 Junction wiring harness AH-4 T03 DT2 2 Transmission oil filter clogging switch E-8
B Terminal 1 Starting switch P-7 CNS1 DT2 12 Intermediate connector Y-2 JM04 — 4 Junction wiring harness AG-3 T04 DT2 2 Steering oil temperature sensor M-5
B06 DT2 2 Brake cooling oil control valve (rear) H-2 CNS2 DT2 12 Intermediate connector X-2 JM05 — 3 Junction wiring harness AH-5 T10 DT2 3 Pitch angle sensor M-9
B07 DT2 2 Brake cooling oil control valve (front) A-5 CNS3 DT2 12 Intermediate connector X-2 JM06 — 3 Junction wiring harness AH-5 T14 DT2 3 Boom positioner sensor K-9
B09 DT2 2 Intermediate connector I-3 COMP DT2 2 Air conditioner compressor B-2 JM07 — 4 Junction wiring harness AF-8 TC200 40 KOMTRAX terminal R-8
B14 DT2 2 Parking brake solenoid valve H-9 D01 2 Diode P-4 KAI 1 Yellow rotary lamp (if equipped) D-7 TCHET X 4 Heater and tachograph unit P-5
B15 DT2 2 Service brake oil pressure switch M-6 D02 2 Diode AB-1 LKO DT2 2 Dump lever kick-out solenoid Z-3 TEL DT2 12 Intermediate connector P-8
B16 DT2 2 Retarder oil pressure switch (front) M-6 D03 2 Diode AB-1 LS 3 Brightness control switch V-1 TFUEL PACKARD 2 Fuel temperature sensor AH-7
B17 DT2 2 Parking brake oil pressure switch M-7 D04 2 Diode AA-2 M01 DT2 2 Coolant level switch H-2 TIM PACKARD 2 Charge temperature sensor AH-7
B18 DT2 2 Retarder proportional pressure reducing valve (rear) M-7 D05 2 Diode AA-2 M02 DT2 2 Hydraulic oil level switch (if equipped) L-5 TWTR PACKARD 2 Engine coolant temperature sensor AG-8
B19 DT2 2 Retarder proportional pressure reducing valve (front) H-9 D06 2 Diode AA-2 M03 DT2 2 Hydraulic oil filter clogging switch (if equipped) L-4 WFM 6 Wiper motor (front) U-1
B21 DT2 2 Accumulator oil pressure switch (front) C-6 D07 2 Diode P-5 M04 DT2 2 Brake oil temperature sensor (center) K-9 WFR 6 Wiper relay (front) U-1
B22 DT2 2 Accumulator oil pressure switch (rear) C-7 D08 2 Diode P-4 M06 DT2 2 Fuel level sensor B-2 WM 4 Intermediate connector P-4
B23 DT2 2 Retarder oil pressure switch (rear) I-9 D09 2 Diode P-5 M07 DT2 2 Brake oil temperature sensor (front) B-2 WPS DT2 12 Wiper and window washer switch S-1
B24 DT2 3 Accumulator oil pressure sensor (rear) C-7 D10 2 Diode AA-2 M08 DT2 2 Retarder oil filter clogging switch (if equipped) G-1 WRF M 6 Working lamp (front) switch P-1
B25 DT2 3 Accumulator oil pressure sensor (front) C-6 D11 2 Diode AB-2 M11 DT2 2 Air cleaner clogging sensor A-4 WRM 4 Wiper motor (rear) J-9
B35 DT2 2 Differential lock solenoid valve (front) A-5 D12 2 Diode AB-2 M-2 Terminal 1 Emergency steering motor G-1
B36 DT2 2 Differential lock solenoid valve (rear) M-7 D13 2 Diode AB-2 M-2 Terminal 1 Emergency steering motor G-1
B39 DT2 2 Differential lock oil pressure switch (front) A-5 D14 2 Diode AB-2 MON AMP 4 Rear view monitor P-6
B40 DT2 2 Differential lock oil pressure switch (Center) J-9 D15 2 Diode N-2 NE FRAMATONE 3 Engine Ne speed sensor AH-5
B41 DT2 2 Differential lock oil pressure switch (rear) K-9 DEF 6 Interaxle differential lockup switch P-3 OF 1 Engine oil filter clogging switch AH-7
BA49 DT2 2 Back buzzer L-9 DEL 6 Right and left differential lockup switch Q-2 OL DT1 2 Engine oil level switch AF-2
BL47 2 Backup lamp M-8 DFS DT2 3 Right and left differential lockup pedal R-2 OP7 M 1 Option selector connector U-1
BL4B 2 Backup lamp L-9 DL DT2 12 Service connector Y-8 P01 3 Headlamp (left) C-1
BLS M 6 Yellow rotary lamp switch (if equipped) P-1 DPC1 20 Machine monitor T-8 P01 3 Headlamp (right) A-4
BP DT 2 Bypass valve solenoid AD-8 DPC2A 18 Machine monitor S-8 P02 3 Front combination lamp (left) C-1
BR Terminal 1 Starting switch Q-6 DPC2B 12 Machine monitor S-7 P02 3 Front combination lamp (right) A-3
BR Terminal 1 Starting motor terminal BR AD-8 DPC3A 18 Machine monitor S-7 P05 DT2 2 Turn lamp (left) M-5
BRC1 DRC 24 Retarder controller AA-8 DPC4 12 Machine monitor T-8 P05A DT2 2 Intermediate connector M-6
BRC2 DRC 40 Retarder controller AA-8 DPC6 8 Machine monitor R-7 P06 DT2 2 Turn lamp (right) D-7
BRC3 DRC 40 Retarder controller Z-8 DPC7 X 4 Service connector R-7 P07 2 Fog lamp (left) (if equipped) D-1
BRC6 X 4 Service connector Y-9 DSL 1 Door switch (left) F-9 P07 2 Fog lamp (right) (if equipped) A-3
BT1 — — Fuse box AA-4 DSR 1 Door switch (right) D-7 P13 2 Horn valve (left) D-1
BT2 — — Fuse box AA-4 DT DT2 8 Intermediate connector E-1 P13 2 Horn valve (right) A-4
BT3 — — Fuse box AA-4 DT1 DT2 6 Intermediate connector A-5 P20 6 Rear combination lamp (left) M-9
BT4 — — Fuse box AA-4 DT2 DT2 12 Intermediate connector B-6 P21 6 Rear combination lamp (right) L-9
BT-1A Terminal 1 Battery N-3 DT4 DT2 12 Intermediate connector J-3 P22 2 Intermediate connector A-9
BT-1B Terminal 1 Battery M-3 DT5 DT2 8 Intermediate connector B-9 PAMB FRAMATONE 3 Ambient pressure sensor AH-4
BT-2A Terminal 1 Battery N-3 DT6 DT2 8 Intermediate connector B-9 PCV1 SUMITOMO 2 Supply pump #1 AD-2
BT-2B Terminal 1 Battery N-3 DT7 DT2 12 Intermediate connector Z-4 PCV2 SUMITOMO 2 Supply pump #2 AE-2
BT-3A Terminal 1 Battery (cold district specification) DT8 DT2 4 Intermediate connector Z-4 PEVA CANNON 3 EGR inlet pressure sensor AC-7
BT-3B Terminal 1 Battery (cold district specification) DT8 DT2 12 Intermediate connector D-1 PFUEL AMP 3 Common rail pressure sensor AF-2
BT-4A Terminal 1 Battery (cold district specification) DT9 DT2 12 Intermediate connector A-3 PHO Terminal 1 Intake air heater relay M-1
BT-4B Terminal 1 Battery (cold district specification) E02 DT2 2 Emergency steering oil pressure switch I-2 PIM CANNON 4 Charge pressure sensor AH-6
BZ2 2 Alarm buzzer V-1 E1 Terminal 1 Alternator (terminal E) AC-6 POIL CANNON 3 Engine oil pressure sensor AG-3
C Terminal 1 Starting switch Q-7 E3 Terminal 1 Chassis ground (battery room) M-1 PWL 1×2 Power window motor (left) M-5
CAB1 SWP 12 Intermediate connector B-6 E3 Terminal 1 Chassis ground (rear frame) AD-3 PWM 6 Power mode selector switch P-3
CAB2 X 8 Intermediate connector B-6 E11 Terminal 1 Intake air heater relay M-1 PWR 1×2 Power window motor (right) (if equipped) E-8
CAN1 3 CAN terminal resistor AG-3 E12 Terminal 1 Intake air heater relay L-1 R01 Relay 5 Engine start relay Z-2
CAN2 DT2 3 CAN terminal resistor S-1 E-2 Terminal 1 Emergency steering motor G-1 R02 Relay 5 Parking brake relay Z-2
CG 2 Cigarette lighter P-3 E-2 Terminal 1 Emergency steering motor G-1 R03 Relay 5 Dust indicator relay Z-2
SEN00534-04
HM400-2 23
HM400-2 25

© 2009 KOMATSU
All Rights Reserved
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HM 400 2 Shop Manual Complete

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SEN00239-09

ARTICULATED DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00239-09

00 Index and foreword SEN00511-09

10 Structure, function and maintenance standard SEN00516-04

20 Standard value table SEN00528-02

30 Testing and adjusting SEN00529-04

Troubleshooting by failure code, Part 3 SEN01110-02 q

50 Disassembly and assembly SEN00531-03

90 Diagrams and drawings SEN00532-04

Foreword and general information SEN00513-04

10 Structure, function and maintenance standard

Proportional reducing valve......................................................................................................... 19

20 Standard value table

30 Testing and adjusting

Testing blow-by pressure............................................................................................................. 14

Troubleshooting by failure code, Part 1 SEN01108-00

Failure code [CA131] Abnormally high throttle sensor signal...................................................... 12

Failure code [CA2249] Low pressure in supply pump 2.............................................................. 44

Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor

S-6 Engine lack output (or lacks power)...................................................................................... 17

50 Disassembly and assembly

Removal and installation of rear rear wheel assembly................................................................ 8

90 Diagrams and drawings

HM400-2 Articulated dump truck

ARTICULATED DUMP TRUCK 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector