HM400-1L Cebd015301 PDF

CEBM015301
Shop
Manual
HM400-1L
ARTICULATED TRUCK
SERIAL NUMBERS HM400-1L A10001 and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
October 2005 Copyright 2005 Komatsu

Printed in USA DataKom Publishing Division
00-1 1
FOREWORD CONTENTS
12
CONTENTS 00
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 1 HM400-1L
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB041800
OPERATION AND MAINTENANCE MANUAL

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM015100
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM015300
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM022209
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D48-2
FIELD ASSEMBLY MANUAL

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEAW003001
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America Corp. Extranet Literature Ordering System.
If the Extranet Literature Ordering System is not available at the distributor location, then the following
Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown
on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax
orders.
HM400-1L pubinfok.fm 2/22/05

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM DataKom Publications and Training Division

AND RETURN TO 440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
SHIP TO PURCHASE ORDER NO.
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT
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IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
QTY. PUBLICATION FORM NO. PARTS BOOK PUBLICATION MODEL NUMBER SERIAL NUMBER
P-Paper DESCRIPTION
➥
M-Microfiche
KDC91E 071403 CURRENT PRICES WILL BE CHARGED

FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 b 00-18 10-7 10-36
● 00-2 b 00-19 10-8 10-37
❍ 00-2-1 b 00-20 10-9 10-38
❍ 00-2-2 b 00-21 10-10 10-39
❍ 00-2-3 b 00-22 10-11 10-40
❍ 00-2-4 b 10-12 10-41
❍ 00-2-5 b 01-1 10-13 10-42
❍ 00-2-6 b 01-2 10-14 10-43
❍ 00-2-7 b 01-3 10-15 10-44
❍ 00-2-8 b 01-4 10-16 10-45
❍ 00-2-9 b 01-5 10-17 10-46
❍ 00-2-10 b 01-6 10-18 10-47
❍ 00-2-11 b 01-7 10-19 10-48
❍ 00-2-12 b 01-8 10-20 10-49
00-3 01-9 10-21 10-50
00-4 01-10 10-22 10-51
00-5 01-11 10-23 10-52
00-6 01-12 10-24 10-53
00-7 01-13 10-25 10-54
00-8 01-14 10-26 10-55
00-9 01-15 10-27 10-56
00-10 01-16 10-28 10-57
00-11 10-29 10-58
00-12 10-1 10-30 10-59
00-13 10-2 10-31 10-60
00-14 10-3 10-32 10-61
00-15 10-4 10-33 10-62
00-16 10-5 10-34 10-63
00-17 10-6 10-35 10-64
HM400-1L HM400-1L 00-2-1 1

FOREWORD
10-65 10-98 10-131 10-164
10-66 10-99 10-132 10-165
10-67 10-100 10-133 10-166
10-68 10-101 10-134 10-167
10-69 10-102 10-135 10-168
10-70 10-103 10-136 10-169
10-71 10-104 10-137 10-170
10-72 10-105 10-138 10-171
10-73 10-106 10-139 10-172
10-74 10-107 10-140 10-173
10-75 10-108 10-141 10-174
10-76 10-109 10-142 10-175
10-77 10-110 10-143 10-176
10-78 10-111 10-144 10-177
10-79 10-112 10-145 10-178
10-80 10-113 10-146 10-179
10-81 10-114 10-147 10-180
10-82 10-115 10-148 10-181
10-83 10-116 10-149 10-182
10-84 10-117 10-150 10-183
10-85 10-118 10-151 10-184
10-86 10-119 10-152 10-185
10-87 10-120 10-153 10-186
10-88 10-121 10-154 10-187
10-89 10-122 10-155 10-188
10-90 10-123 10-156 10-189
10-91 10-124 10-157 10-190
10-92 10-125 10-158 10-191
10-93 10-126 10-159 10-192
10-94 10-127 10-160 10-193
10-95 10-128 10-161 10-194
10-96 10-129 10-162 10-195
10-97 10-130 10-163 10-196
00-2-2 1 HM400-1L
FOREWORD
10-197 ❍ 20-5 b ❍ 20-38 b ❍ 20-71 b
10-198 ❍ 20-6 b ❍ 20-39 b ❍ 20-72 b
10-199 ❍ 20-7 b ❍ 20-40 b ❍ 20-73 b
10-200 ❍ 20-8 b ❍ 20-41 b ❍ 20-74 b
10-201 ❍ 20-9 b ❍ 20-42 b ❍ 20-75 b
10-202 ❍ 20-10 b ❍ 20-43 b ❍ 20-76 b
10-203 ❍ 20-11 b ❍ 20-44 b ❍ 20-77 b
10-204 ❍ 20-12 b ❍ 20-45 b ❍ 20-78 b
10-205 ❍ 20-13 b ❍ 20-46 b ❍ 20-79 b
10-206 ❍ 20-14 b ❍ 20-47 b ❍ 20-80 b
10-207 ❍ 20-15 b ❍ 20-48 b ❍ 20-81 b
10-208 ❍ 20-16 b ❍ 20-49 b ❍ 20-82 b
10-209 ❍ 20-17 b ❍ 20-50 b ❍ 20-83 b
10-210 ❍ 20-18 b ❍ 20-51 b ❍ 20-84 b
10-211 ❍ 20-19 b ❍ 20-52 b ❍ 20-85 b
10-212 ❍ 20-20 b ❍ 20-53 b ❍ 20-86 b
10-213 ❍ 20-21 b ❍ 20-54 b ❍ 20-87 b
10-214 ❍ 20-22 b ❍ 20-55 b ❍ 20-88 b
10-215 ❍ 20-23 b ❍ 20-56 b ❍ 20-89 b
10-216 ❍ 20-24 b ❍ 20-57 b ❍ 20-90 b
10-217 ❍ 20-25 b ❍ 20-58 b ❍ 20-91 b
10-218 ❍ 20-26 b ❍ 20-59 b ❍ 20-92 b
10-219 ❍ 20-27 b ❍ 20-60 b ❍ 20-93 b
10-220 ❍ 20-28 b ❍ 20-61 b ❍ 20-94 b
10-221 ❍ 20-29 b ❍ 20-62 b ❍ 20-95 b
10-222 ❍ 20-30 b ❍ 20-63 b ❍ 20-96 b
10-223 ❍ 20-31 b ❍ 20-64 b ❍ 20-97 b
10-224 ❍ 20-32 b ❍ 20-65 b ❍ 20-98 b
❍ 20-33 b ❍ 20-66 b ❍ 20-99 b
❍ 20-1 b ❍ 20-34 b ❍ 20-67 b ❍ 20-100 b
❍ 20-2 b ❍ 20-35 b ❍ 20-68 b ❍ 20-101 b
❍ 20-3 b ❍ 20-36 b ❍ 20-69 b ❍ 20-102 b
❍ 20-4 b ❍ 20-37 b ❍ 20-70 b ❍ 20-103 b
HM400-1L 00-2-3 1
FOREWORD
❍ 20-104 b ❍ 20-230 b ❍ 20-302 b ❍ 20-335 b
❍ 20-105 b ❍ 20-231 b ❍ 20-303 b ❍ 20-336 b
❍ 20-106 b ❍ 20-232 b ❍ 20-304 b ❍ 20-337 b
❍ 20-233 b ❍ 20-305 b ❍ 20-338 b
❍ 20-201 b ❍ 20-234 b ❍ 20-306 b ❍ 20-339 b
❍ 20-202 b ❍ 20-235 b ❍ 20-307 b ❍ 20-340 b
❍ 20-203 b ❍ 20-236 b ❍ 20-308 b ❍ 20-341 b
❍ 20-204 b ❍ 20-237 b ❍ 20-309 b ❍ 20-342 b
❍ 20-205 b ❍ 20-238 b ❍ 20-310 b ❍ 20-343 b
❍ 20-206 b ❍ 20-239 b ❍ 20-311 b ❍ 20-344 b
❍ 20-207 b ❍ 20-240 b ❍ 20-312 b ❍ 20-345 b
❍ 20-208 b ❍ 20-241 b ❍ 20-313 b ❍ 20-346 b
❍ 20-209 b ❍ 20-242 b ❍ 20-314 b ❍ 20-347 b
❍ 20-210 b ❍ 20-243 b ❍ 20-315 b ❍ 20-348 b
❍ 20-211 b ❍ 20-244 b ❍ 20-316 b ❍ 20-349 b
❍ 20-212 b ❍ 20-245 b ❍ 20-317 b ❍ 20-350 b
❍ 20-213 b ❍ 20-246 b ❍ 20-318 b ❍ 20-351 b
❍ 20-214 b ❍ 20-247 b ❍ 20-319 b ❍ 20-352 b
❍ 20-215 b ❍ 20-248 b ❍ 20-320 b ❍ 20-353 b
❍ 20-216 b ❍ 20-249 b ❍ 20-321 b ❍ 20-354 b
❍ 20-217 b ❍ 20-250 b ❍ 20-322 b ❍ 20-355 b
❍ 20-218 b ❍ 20-251 b ❍ 20-323 b ❍ 20-356 b
❍ 20-219 b ❍ 20-252 b ❍ 20-324 b ❍ 20-357 b
❍ 20-220 b ❍ 20-253 b ❍ 20-325 b ❍ 20-358 b
❍ 20-221 b ❍ 20-254 b ❍ 20-326 b ❍ 20-359 b
❍ 20-222 b ❍ 20-255 b ❍ 20-327 b ❍ 20-360 b
❍ 20-223 b ❍ 20-256 b ❍ 20-328 b ❍ 20-361 b
❍ 20-224 b ❍ 20-257 b ❍ 20-329 b ❍ 20-362 b
❍ 20-225 b ❍ 20-258 b ❍ 20-330 b ❍ 20-363 b
❍ 20-226 b ❍ 20-259 b ❍ 20-331 b ❍ 20-364 b
❍ 20-227 b ❍ 20-260 b ❍ 20-332 b ❍ 20-365 b
❍ 20-228 b ❍ 20-333 b ❍ 20-366 b
❍ 20-229 b ❍ 20-301 b ❍ 20-334 b ❍ 20-367 b
00-2-4 1 HM400-1L
FOREWORD
❍ 20-368 b ❍ 20-410 b ❍ 20-443 b ❍ 20-476 b
❍ 20-369 b ❍ 20-411 b ❍ 20-444 b ❍ 20-477 b
❍ 20-370 b ❍ 20-412 b ❍ 20-445 b ❍ 20-478 b
❍ 20-371 b ❍ 20-413 b ❍ 20-446 b ❍ 20-479 b
❍ 20-372 b ❍ 20-414 b ❍ 20-447 b ❍ 20-480 b
❍ 20-373 b ❍ 20-415 b ❍ 20-448 b ❍ 20-481 b
❍ 20-374 b ❍ 20-416 b ❍ 20-449 b ❍ 20-482 b
❍ 20-375 b ❍ 20-417 b ❍ 20-450 b ❍ 20-483 b
❍ 20-376 b ❍ 20-418 b ❍ 20-451 b ❍ 20-484 b
❍ 20-377 b ❍ 20-419 b ❍ 20-452 b ❍ 20-485 b
❍ 20-378 b ❍ 20-420 b ❍ 20-453 b ❍ 20-486 b
❍ 20-379 b ❍ 20-421 b ❍ 20-454 b ❍ 20-487 b
❍ 20-380 b ❍ 20-422 b ❍ 20-455 b ❍ 20-488 b
❍ 20-381 b ❍ 20-423 b ❍ 20-456 b ❍ 20-489 b
❍ 20-382 b ❍ 20-424 b ❍ 20-457 b ❍ 20-490 b
❍ 20-383 b ❍ 20-425 b ❍ 20-458 b ❍ 20-491 b
❍ 20-384 b ❍ 20-426 b ❍ 20-459 b ❍ 20-492 b
❍ 20-385 b ❍ 20-427 b ❍ 20-460 b ❍ 20-493 b
❍ 20-386 b ❍ 20-428 b ❍ 20-461 b ❍ 20-494 b
❍ 20-387 b ❍ 20-429 b ❍ 20-462 b ❍ 20-495 b
❍ 20-388 b ❍ 20-430 b ❍ 20-463 b ❍ 20-496 b
❍ 20-389 b ❍ 20-431 b ❍ 20-464 b ❍ 20-497 b
❍ 20-390 b ❍ 20-432 b ❍ 20-465 b ❍ 20-498 b
❍ 20-433 b ❍ 20-466 b ❍ 20-499 b
❍ 20-401 b ❍ 20-434 b ❍ 20-467 b ❍ 20-500 b
❍ 20-402 b ❍ 20-435 b ❍ 20-468 b ❍ 20-501 b
❍ 20-403 b ❍ 20-436 b ❍ 20-469 b ❍ 20-502 b
❍ 20-404 b ❍ 20-437 b ❍ 20-470 b ❍ 20-503 b
❍ 20-405 b ❍ 20-438 b ❍ 20-471 b ❍ 20-504 b
❍ 20-406 b ❍ 20-439 b ❍ 20-472 b ❍ 20-505 b
❍ 20-407 b ❍ 20-440 b ❍ 20-473 b ❍ 20-506 b
❍ 20-408 b ❍ 20-441 b ❍ 20-474 b ❍ 20-507 b
❍ 20-409 b ❍ 20-442 b ❍ 20-475 b ❍ 20-508 b
HM400-1L 00-2-5 1
FOREWORD
❍ 20-509 b ❍ 20-542 b ❍ 20-575 b ❍ 20-608 b
❍ 20-510 b ❍ 20-543 b ❍ 20-576 b ❍ 20-609 b
❍ 20-511 b ❍ 20-544 b ❍ 20-577 b ❍ 20-610 b
❍ 20-512 b ❍ 20-545 b ❍ 20-578 b ❍ 20-611 b
❍ 20-513 b ❍ 20-546 b ❍ 20-579 b ❍ 20-612 b
❍ 20-514 b ❍ 20-547 b ❍ 20-580 b ❍ 20-613 b
❍ 20-515 b ❍ 20-548 b ❍ 20-581 b ❍ 20-614 b
❍ 20-516 b ❍ 20-549 b ❍ 20-582 b ❍ 20-615 b
❍ 20-517 b ❍ 20-550 b ❍ 20-583 b ❍ 20-616 b
❍ 20-518 b ❍ 20-551 b ❍ 20-584 b
❍ 20-519 b ❍ 20-552 b ❍ 20-585 b ❍ 20-701 b
❍ 20-520 b ❍ 20-553 b ❍ 20-586 b ❍ 20-702 b
❍ 20-521 b ❍ 20-554 b ❍ 20-587 b ❍ 20-703 b
❍ 20-522 b ❍ 20-555 b ❍ 20-588 b ❍ 20-704 b
❍ 20-523 b ❍ 20-556 b ❍ 20-589 b ❍ 20-705 b
❍ 20-524 b ❍ 20-557 b ❍ 20-590 b ❍ 20-706 b
❍ 20-525 b ❍ 20-558 b ❍ 20-591 b ❍ 20-707 b
❍ 20-526 b ❍ 20-559 b ❍ 20-592 b ❍ 20-708 b
❍ 20-527 b ❍ 20-560 b ❍ 20-593 b ❍ 20-709 b
❍ 20-528 b ❍ 20-561 b ❍ 20-594 b ❍ 20-710 b
❍ 20-529 b ❍ 20-562 b ❍ 20-595 b ❍ 20-711 b
❍ 20-530 b ❍ 20-563 b ❍ 20-596 b ❍ 20-712 b
❍ 20-531 b ❍ 20-564 b ❍ 20-597 b ❍ 20-713 b
❍ 20-532 b ❍ 20-565 b ❍ 20-598 b ❍ 20-714 b
❍ 20-533 b ❍ 20-566 b ❍ 20-599 b ❍ 20-715 b
❍ 20-534 b ❍ 20-567 b ❍ 20-600 b ❍ 20-716 b
❍ 20-535 b ❍ 20-568 b ❍ 20-601 b ❍ 20-717 b
❍ 20-536 b ❍ 20-569 b ❍ 20-602 b ❍ 20-718 b
❍ 20-537 b ❍ 20-570 b ❍ 20-603 b ❍ 20-719 b
❍ 20-538 b ❍ 20-571 b ❍ 20-604 b ❍ 20-720 b
❍ 20-539 b ❍ 20-572 b ❍ 20-605 b ❍ 20-721 b
❍ 20-540 b ❍ 20-573 b ❍ 20-606 b ❍ 20-722 b
❍ 20-541 b ❍ 20-574 b ❍ 20-607 b ❍ 20-723 b
00-2-6 1 HM400-1L
FOREWORD
❍ 20-724 b ❍ 20-757 b ❍ 20-790 b ❍ 20-920 b
❍ 20-725 b ❍ 20-758 b ❍ 20-791 b ❍ 20-921 b
❍ 20-726 b ❍ 20-759 b ❍ 20-792 b ❍ 20-922 b
❍ 20-727 b ❍ 20-760 b ❍ 20-793 b ❍ 20-923 b
❍ 20-728 b ❍ 20-761 b ❍ 20-794 b ❍ 20-924 b
❍ 20-729 b ❍ 20-762 b ❍ 20-795 b ❍ 20-925 b
❍ 20-730 b ❍ 20-763 b ❍ 20-796 b ❍ 20-926 b
❍ 20-731 b ❍ 20-764 b ❍ 20-797 b ❍ 20-927 b
❍ 20-732 b ❍ 20-765 b ❍ 20-798 b ❍ 20-928 b
❍ 20-733 b ❍ 20-766 b ❍ 20-799 b ❍ 20-929 b
❍ 20-734 b ❍ 20-767 b ❍ 20-800 b ❍ 20-930 b
❍ 20-735 b ❍ 20-768 b ❍ 20-801 b ❍ 20-931 b
❍ 20-736 b ❍ 20-769 b ❍ 20-802 b ❍ 20-932 b
❍ 20-737 b ❍ 20-770 b ❍ 20-933 b
❍ 20-738 b ❍ 20-771 b ❍ 20-901 b ❍ 20-934 b
❍ 20-739 b ❍ 20-772 b ❍ 20-902 b ❍ 20-935 b
❍ 20-740 b ❍ 20-773 b ❍ 20-903 b ❍ 20-936 b
❍ 20-741 b ❍ 20-774 b ❍ 20-904 b ❍ 20-937 b
❍ 20-742 b ❍ 20-775 b ❍ 20-905 b ❍ 20-938 b
❍ 20-743 b ❍ 20-776 b ❍ 20-906 b ❍ 20-939 b
❍ 20-744 b ❍ 20-777 b ❍ 20-907 b ❍ 20-940 b
❍ 20-745 b ❍ 20-778 b ❍ 20-908 b ❍ 20-941 b
❍ 20-746 b ❍ 20-779 b ❍ 20-909 b ❍ 20-942 b
❍ 20-747 b ❍ 20-780 b ❍ 20-910 b ❍ 20-943 b
❍ 20-748 b ❍ 20-781 b ❍ 20-911 b ❍ 20-944 b
❍ 20-749 b ❍ 20-782 b ❍ 20-912 b ❍ 20-945 b
❍ 20-750 b ❍ 20-783 b ❍ 20-913 b ❍ 20-946 b
❍ 20-751 b ❍ 20-784 b ❍ 20-914 b ❍ 20-947 b
❍ 20-752 b ❍ 20-785 b ❍ 20-915 b ❍ 20-948 b
❍ 20-753 b ❍ 20-786 b ❍ 20-916 b ❍ 20-949 b
❍ 20-754 b ❍ 20-787 b ❍ 20-917 b ❍ 20-950 b
❍ 20-755 b ❍ 20-788 b ❍ 20-918 b ❍ 20-951 b
❍ 20-756 b ❍ 20-789 b ❍ 20-919 b ❍ 20-952 b
HM400-1L 00-2-7 1
FOREWORD
❍ 20-953 b 30-33 30-66
❍ 20-954 b 30-1 30-34 30-67
❍ 20-955 b 30-2 30-35 30-68
❍ 20-956 b 30-3 30-36 30-69
❍ 20-957 b 30-4 30-37 30-70
❍ 20-958 b 30-5 30-38 30-71
❍ 20-959 b 30-6 30-39 30-72
❍ 20-960 b 30-7 30-40 30-73
❍ 20-961 b 30-8 30-41 30-74
❍ 20-962 b 30-9 30-42 30-75
❍ 20-963 b 30-10 30-43 30-76
❍ 20-964 b 30-11 30-44 30-77
30-12 30-45 30-78
❍ 20-1001 b 30-13 30-46 30-79
❍ 20-1002 b 30-14 30-47 30-80
❍ 20-1003 b 30-15 30-48 30-81
❍ 20-1004 b 30-16 30-49 30-82
❍ 20-1005 b 30-17 30-50 30-83
❍ 20-1006 b 30-18 30-51 30-84
❍ 20-1007 b 30-19 30-52 30-85
❍ 20-1008 b 30-20 30-53 30-86
❍ 20-1009 b 30-21 30-54 30-87
❍ 20-1010 b 30-22 30-55 30-88
❍ 20-1011 b 30-23 30-56 30-89
❍ 20-1012 b 30-24 30-57 30-90
❍ 20-1013 b 30-25 30-58 30-91
❍ 20-1014 b 30-26 30-59 30-92
❍ 20-1015 b 30-27 30-60 30-93
❍ 20-1016 b 30-28 30-61 30-94
❍ 20-1017 b 30-29 30-62 30-95
❍ 20-1018 b 30-30 30-63 30-96
❍ 20-1019 b 30-31 30-64 30-97
❍ 20-1020 b 30-32 30-65 30-98
00-2-8 1 HM400-1L
FOREWORD
30-99 30-132 30-165 30-198
30-100 30-133 30-166 30-199
30-101 30-134 30-167 30-200
30-102 30-135 30-168 30-201
30-103 30-136 30-169 30-202
30-104 30-137 30-170 30-203
30-105 30-138 30-171 30-204
30-106 30-139 30-172 30-205
30-107 30-140 30-173 30-206
30-108 30-141 30-174 30-207
30-109 30-142 30-175 30-208
30-110 30-143 30-176 30-209
30-111 30-144 30-177 30-210
30-112 30-145 30-178 30-211
30-113 30-146 30-179 30-212
30-114 30-147 30-180 30-213
30-115 30-148 30-181 30-214
30-116 30-149 30-182 30-215
30-117 30-150 30-183 30-216
30-118 30-151 30-184 30-217
30-119 30-152 30-185 30-218
30-120 30-153 30-186 30-219
30-121 30-154 30-187 30-220
30-122 30-155 30-188 30-221
30-123 30-156 30-189 30-222
30-124 30-157 30-190 30-223
30-125 30-158 30-191 30-224
30-126 30-159 30-192 30-225
30-127 30-160 30-193 30-226
30-128 30-161 30-194 30-227
30-129 30-162 30-195 30-228
30-130 30-163 30-196 30-229
30-131 30-164 30-197 30-230
HM400-1L 00-2-9 1
FOREWORD
30-231 30-264 30-297 30-330
30-232 30-265 30-298 30-331
30-233 30-266 30-299 30-332
30-234 30-267 30-300 30-333
30-235 30-268 30-301 30-334
30-236 30-269 30-302 30-335
30-237 30-270 30-303 30-336
30-238 30-271 30-304 30-337
30-239 30-272 30-305 30-338
30-240 30-273 30-306 30-339
30-241 30-274 30-307 30-340
30-242 30-275 30-308 30-341
30-243 30-276 30-309 30-342
30-244 30-277 30-310 30-343
30-245 30-278 30-311 30-344
30-246 30-279 30-312 30-345
30-247 30-280 30-313 30-346
30-248 30-281 30-314 30-347
30-249 30-282 30-315 30-348
30-250 30-283 30-316
30-251 30-284 30-317 90-1
30-252 30-285 30-318 90-2
30-253 30-286 30-319 90-3
30-254 30-287 30-320 90-4
30-255 30-288 30-321 90-5
30-256 30-289 30-322 90-6
30-257 30-290 30-323 90-7
30-258 30-291 30-324 90-8
30-259 30-292 30-325 90-9
30-260 30-293 30-326 90-10
30-261 30-294 30-327 90-11
30-262 30-295 30-328 90-12
30-263 30-296 30-329 90-13
00-2-10 1 HM400-1L
FOREWORD
90-14 90-47
90-15 90-48
90-16 90-49
90-17 90-50
90-18 90-51
90-19 90-52
90-20 90-53
90-21 90-54
90-22 90-55
90-23 90-56
90-24 90-57
90-25 90-58
90-26 90-59
90-27 90-60
90-28
90-29
90-30
90-31
90-32
90-33
90-34
90-35
90-36
90-37
90-38
90-39
90-40
90-41
90-42
90-43
90-44
90-45
90-46
HM400-1L 00-2-11 1
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK 00
Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not possi-
machine. ble, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
● Always wear safety glasses when hitting parts with a 3. When disassembling or assembling, support the
hammer. machine with blocks, jacks or stands before starting
● Always wear safety glasses when grinding parts with a work.
grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or hydrau-
before starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to pre-
work, hang UNDER REPAIR signs on the controls in vent the oil from spurting out. Before disconnecting or
the operator's compartment. removing components of the oil, water or air circuits,
first remove the pressure completely from the circuit.
5. Keep all tools in good condition and learn the correct
way to use them. 2. The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
6. Decide a place in the repair workshop to keep tools and oil and water to cool before carrying out any work on
removed parts. Always keep the tools and parts in their the oil or water circuits.
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke 3. Before starting work, remove the leads from the battery.
only in the areas provided for smoking. Never smoke ALWAYS remove the lead from the negative (-) termi-
while working. nal first.
HM400-1L 00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in posi-
tion on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing elec-
trical parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed cor-
rectly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure-
ments.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4 HM400-1L
FOREWORD GENERAL
12
GENERAL 00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under-
standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under-
stand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at comple-
tion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
HM400-1L 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP
REVISIONS
MANUAL
00
00
Revised pages are shown at the LIST OF REVISED PAGES

VOLUMES 00
between the title page and SAFETY page.
Shop manuals are issued as a guide to carrying out repairs. SYMBOLS 00
They are divided as follows:

So that the shop manual can be of ample practical use,
Chassis volume: Issued for every machine model important places for safety and quality are marked with the
Engine volume: Issued for each engine series following symbols.
Electrical volume: Each issued as one to cover all models

Attachment volume: Each issued as one to cover all models Symbol Item Remarks
Special safety precautions are
These various volumes are designed to avoid duplication of Safety necessary when performing the
information. Therefore to deal with all repairs for any model, work.
it is necessary that chassis, engine, electrical and attachment
be available. Special technical precautions or
other precautions for preserving
★ Caution
standards are necessary when
DISTRIBUTION AND UPDATING 00
performing the work.

Any additions, amendments or other changes will be sent to Weight of parts or systems. Cau-
your distributors. Get the most up-to-date information before tion necessary when selecting
Weight
you start any work. hoisting wire or when working
posture is important, etc.
FILING METHOD 00
Places that require special atten-
Tightening
tion for tightening torque during
1. See the page number on the bottom of the page. File the torque
assembly.
pages in correct order.
2. Following examples show how to read the page number: Places to be coated with adhe-
Coat
Example: sives and lubricants etc.
Places where oil, water or fuel

10 - 3 Oil, water
must be added, and the capacity.
Item number (10. Structure and Function) Places where oil or water must
Drain be drained, and quantity to be
Consecutive page number for each item drained.
3. Additional pages: Additional pages are indicated by a

hyphen (-) and numbered after the page number. File as
in the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK 00
When a manual is revised, an edition mark (123…) is

recorded on the bottom outside corner of the pages.
00-6 HM400-1L
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
can result. Hooks have maximum strength at the middle
portion.
HOISTING 00
WARNING! Heavy parts (25 kg or more)

must be lifted with a hoist etc. In
the DISASSEMBLY AND
ASSEMBLY section, every part
weighing 25 kg or more is indi-
cated clearly with the symbol
3. Do not sling a heavy load with one rope alone, but sling
● If a part cannot be smoothly removed from the machine with two or more ropes symmetrically wound on to the
by hoisting, the following checks should be made: load.
1. Check for removal of all bolts fastening the part to the
WARNING! Slinging with one rope may
relative parts.
cause turning of the load during
2. Check for existence of another part causing interface
hoisting, untwisting of the rope,
with the part to be removed.
or slipping of the rope from its
original winding position on the
WIRE ROPES 00
load, which can result in a dan-

gerous accident
1. Use adequate ropes depending on the weight of parts to
be hoisted, referring to the table below: 4. Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load with
Wire ropes
two or more ropes, the force subjected to each rope will
(Standard “Z” or “S” twist ropes without galvanizing)
increase with the hanging angles. The table below
Rope diameter Allowable load shows the variation of allowable load (kg) when hoist-
ing is made with two ropes, each of which is allowed to
mm kN tons
sling up to 1000 kg vertically, at various hanging angles.
10 9.8 1.0 When two ropes sling a load vertically, up to 2000 kg of
total weight can be suspended. This weight becomes
11.5 13.7 1.4
1000 kg when two ropes make a 120° hanging angle. On
12.5 15.7 1.6 the other hand, two ropes are subject to an excessive-
force as large as 4000 kg if they sling a 2000 kg load at a
14 21.6 2.2
lifting angle of 150°.
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
HM400-1L 00-7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 00
k Before carrying out the following work, release the residual pres-
sure from the hydraulic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank,

some hydraulic oil flows out when the hose is disconnected. Accord-
ingly, prepare an oil receiving container.
Disconnection 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure
from hydraulic tank.
2. Hold adapter (1) and push hose joint (2) into mating adapter (3).
(See Fig. 1)
★ The adapter can be pushed in about 3.5 mm.
★ Do not hold rubber cap portion (4).
3. After hose joint (2) is pushed into adapter (3), press rubber cap
portion (4) against (3) until it clicks. (See Fig. 2)
4. Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3)
★ Since some hydraulic oil flows out, prepare an oil receiving
container.
Connection 00
1. Hold hose adapter (1) or hose (5) and insert it in mating adapter
(3), aligning them with each other. (See Fig. 4)
★ 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. (See Fig. 5)
★ When the hose is pulled back, the rubber cap portion moves
toward the hose about 3.5 mm. This does not indicate abnor-
mality, however.
00-8 HM400-1L
Type 2 Type 3
1. Hold the mouthpiece of the tightening portion and 1. Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the hexago- ring (1) contacts contact surface a of the hexago-
nal portion at the male end. nal portion at the male end.
2. Hold in the condition in Step 1, and turn lever (4) 2. Hold in the condition in Step 1, and push until
to the right (clockwise). cover (3) contacts contact surface a of the hexag-
onal portion at the male end.
Disassembly
3. Hold in the condition in Steps 1 and 2, and pull 3. Hold in the condition in Steps 1 and 2, and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
● Hold the mouthpiece of the tightening portion and ● Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the hexago- ring (1) contacts contact surface a of the hexago-
nal portion at the male end to connect it. nal portion at the male end to connect it.
Connection
HM400-1L 00-9
FOREWORD COATING MATERIALS
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers, plas-
tics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket seal- ● Used as sealant for flange surfaces and bolts
ant at high temperature locations; used to pre-
LG-3 790-129-9070 1 kg Can vent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-10 HM400-1L
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
● Used as sealant for mating surfaces of final
drive case, transmission case.
● Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket seal- ● Features: Silicon based, resistant to heat,
ant cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case,
etc.
● Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube
● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
● Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
● Used as lubricant for sliding parts (to pre-
LM-G 09940-00051 60 g Can
Molybdenum
vent squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water or
Grease SYG2-160CA
steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
HM400-1L 00-11
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-12 HM400-1L
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm kgm
14 19 24.5 ±4.9 2.5 ±0.5
18 24 49 ±19.6 5 ±2
22 27 78.5 ±19.6 8 ±2
24 32 137.3 ±29.4 14 ±3
30 36 176.5 ±29.4 18 ±3
33 41 196.1 ±49 20 ±5
36 46 245.2 ±49 25 ±5
42 55 294.2 ±49 30 ±5
HM400-1L 00-13
12
TIGHTENING TORQUE FOR 102 ENGINE SERIES 00
1. Bolts and Nuts

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
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
2. Eye Joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
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
3. Tapered Screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE
SEAL TYPE) 00
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Taper seal Face seal type

type
Nominal size Width across
of hose flats Nominal thread size -
Range Target Thread size Threads per inch, Root diameter (mm)
(mm) Thread series (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
00-14 HM400-1L
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread size - Root diameter (mm)
Range Target (mm) Threads per inch, (Reference)
Thread series
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(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 – –
HM400-1L 00-15
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 HM400-1L
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
METHOD OF USING THE CONVERSION TABLE 00
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.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
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
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
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
HM400-1L 00-17
12
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
00-18 HM400-1L
12
Liter to U.S. Gallon 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
Liter to U.K. Gallon 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
HM400-1L 00-19
12
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 1352.63 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
00-20 HM400-1L
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
HM400-1L 00-21
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, con-
sider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column
at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°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 81 117.8
-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
00-22 HM400-1L
01 GENERAL
SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
ARCTIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE
BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
FINAL DRIVE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
DRIVE AXLE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
COOLING SYSTEM TEST KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-16
HM400-1L 01-1
GENERAL SPECIFICATION DRAWING
12
SPECIFICATION DRAWING
01-2 HM400-1L
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model HM400-1L
Serial Number A10001 and up
Unloaded 30,350 kg 66,910 lbs

Max payload 37,000 kg 81,571 lbs
Overall weight 67,350 kg 148,481 lbs
Weight
Unloaded (front wheel) 55.4 kg 122 lbs

(front rear wheel) 22.3 kg 49 lbs
(rear rear wheel) 22.3 kg 49 lbs
Fully-loaded (front wheel) 28.4 kg 63 lbs
(front rear wheel) 35.8 kg 79 lbs
(rear rear wheel) 35.8 kg 79 lbs
Dump body capacity Struck 16.5 m3 22 yd3

Performance
Heaped (2:1) 22.5 m3 29 yd3

Max travel speed 58.6 km/h 36 mph
Gradeability (degrees) 27° 27°
Min. turning radius 8,710 mm 9.5 yd
Dumping angle (angle to ground) (degrees) 70° 70°
mm IN
Overall length 11,025 434

Overall width 3,450 136
Dimensions
Overall height 3,700 146

Wheelbase (front wheel - front rear wheel) 4,350 171
Wheelbase (front rear wheel - rear rear wheel) 1,970 78
Tread Front tires 2,690 106

Rear tires 2,690 106
Front rear tires 2,690 106
Rear rear wheel 600 24
Engine Komatsu SAA6D140E-3 diesel
Model 4-cycle, water-cooled, in-line 6 cylinder, direct

injection, with turbocharger and air-cooled
Type Aftercooled
No. of cylinders -- bore x stroke 6 - 140 X 165 mm

Engine
Piston displacement 15.24 liters (15,240 cc)
Flywheel Horsepower @ 2,000 rpm 331 kW (444 HP)
Maximum torque @ 1,400 rpm 2,045 Nm (1,508 lbf/ft)

Fuel consumption (rated) 204 g/kWh (152 g/HPh)
Starting motor 24V, 11 kW

Alternator 24V, 60 A
Battery 1300Amp Cold Cranking, 12V x 2
01-3 HM400-1L
Torque converter Type 3-element, 1-stage, 2-phase

Lock-up clutch 39. Hydraulically-actuated, wet-type, single-disc
clutch
Transmission Type TORQFLOW multiple-axle transmission, fully
Power train
automatic, electrically-hydraulically actuated,

force-feed type pump lubrication type
No. of Speeds F6, R2
Reduction gear Type Straight bevel gear, splash lubrication
Reduction Ratio 3.417
Differential type Straight bevel gear, splash lubrication
Final drive Type Planetary gear, splash lubrication
Reduction ratio 4.941
Type Fully hydraulic

Travel system
Axle type Front axle Independent suspension (MacPherson type)

Suspension
Front rear axle Independent suspension (MacPherson type)

Rear rear axle Independent suspension (MacPherson type)
Suspension method Front axle Hydropneumatic type
Rear rear axle Hydropneumatic type
Size and number Front tire 29.5 R25 x 2

Front rear tire 29.5 R25 x 2
Tires
Rear rear tire 29.5 R25 x 2

Tire inflation pressure 3.8 kg/cm2 (54 psi)
Main brake Front wheel Independent front and rear system brake, sealed,
Front rear wheel wet-type, multiple disc, hydraulically operated type
Rear rear wheel
Brakes
Spring-boosted, caliper disc type

Parking brake
Independent front and rear system brake, sealed,
Retarder wet-type, multiple disc, hydraulically operated type
01-4 HM400-1L
12
For steering - type Gear pump

Discharge amount (L/min) 218
(at engine rated speed of 2000 rpm)
For hoist - type Gear pump
Discharge amount (L/min) 18.5
For transmission, rake cooling - type Gear pump
Hydraulic pump, motor

For brake cooling - type Gear pump
For brake - type Gear pump
Hydraulic

system

For differential lock front - type Gear pump
For differential lock motor - type Gear pump
For differential lock center, rear - type Gear pump
Hoist cylinder - type 2- stage piston type (only second stage double-acting)
Cylinder
Number of bores (1st and 2nd) x stroke 2- (160mm-120mm) x 3,232mm
Steering cylinder - type Piston type, double acting

Number of bores x stroke 2 - 120mm x 525mm
HM400-1L 01-5
GENERAL WEIGHT TABLE
12
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
kg lb
HM400-1L Serial Numbers A10001 and up 30,350 66,910
Engine 1,470 3,241
Output shaft assembly 88 194
Cooling assembly 349 769
Fuel tank (individual part) 200 441
Torque converter assembly 282 662
Transmission assembly 1,324 2,919
Drive shaft assembly 295 650
Front axle assembly 2,131 4,698
Differential 428 944
Final drive 1,060 2,337
Center axle assembly 2,423 5,342
Final drive 1,047 2,308
Rear axle assembly 2,297 5,064
Final drive 1047 2,308
Front suspension cylinder 91.2 201
Rear suspension cylinder 78.2 172
Oscillation hitch assembly 851.1 1,876
Front frame 1,585 3,494
Rear frame 2,000 4,409
Cab (including platform, interior components) 652 1,437
Operator’s seat 56.1 124
Steering cylinder (one side) 65.6 145
Hoist cylinder (one side) Rear frame 254 560
Flow amp valve 29 64
Hoist valve 63 139
Hydraulic tank 240 529
Hydraulic pump (SBL(1)21) 2.6 6
Hydraulic pump (SAR(3)80+(1)25) 19.4 43
Hydraulic pump (SAR(3)100) 13 29
Hydraulic pump (SAR(3)100+100+(1)8) 35.8 79
Hydraulic pump (SAR(3)100+(1)12+8) 23.9 53
Hydraulic pump (SBR(1)8+8) 4.7 10
Hydraulic motor 1.9 4
Body assembly 4,232 9,330
01-6 HM400-1L
GENERAL FUEL, COOLANT AND LUBRICANTS
12
FUEL, COOLANT AND LUBRICANTS
It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the
quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your Komatsu distributor. The
following table shows specified fuel, coolant and lubricants recommended for this machine.
AMBIENT TEMPERATURE CAPACITY

FLUID
RESERVOIR -22 -4 14 32 50 68 86 104°F
TYPE Specified Refill
-30 -20 -10 0 10 20 30 40°C
SAE 10W
140L 132 L
SAE 10W-30
Engine oil pan 37.9 gal 34.8 gal
SAE 15W-40
Engine oil
SAE 30
Transmission SAE 10W 164 L 140 L
case SAE 30W 43.3 gal 37.0 gal
360 L 360 L
Axle - each Axle oil See page 9, "Drive Axle Oil Specifications”
95 gal 95 gal
SAE 10W
Hydraulic 1075 L 735 L 194
SAE 15W-40
system 284 gal gal
Engine oil
SAE 10W-30
Brake system 42 L 31 L
SAE 10W
11.1 gal 8.2 gal
ASTM D975 No. 2 1425 L
Fuel tank Diesel fuel 376.2 gal --
ASTM D975 No. 1
All lubrication Komatsu Super Grease or NLGI No.2 Multi-purpose lithium grease
Grease Fill as instructed
fittings with 3% - 5% molybdenum disulfide
Cooling See "Coolant specifications", in this section 319 L
Coolant --
system 84 gal
API: American Petroleum Institute

ASTM: American Society of Testing and Materials
NLGI: National Lubricating Grease Institute
SAE: Society of Automotive Engineers
Specified Capacity: Total amount of oil including oil for components and piping.
Refill Capacity: Amount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20°C (-4°F). Consult your Komatsu
distributor for your specific needs.
HM400-1L 01-7
12
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
Oil performance recommendations are as follows:
The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in
maintaining engine performance and durability.
Komatsu Engine Oil or multi-viscosity engine oil meeting American Petroleum Institute (API) performance classification
CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
NOTICE:
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil
is not yet available. If API classification CC or CC/CD is used, reduce the engine oil change interval by half.
A sulfated ash limit of 1.0 to 1.5 mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed
on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage
and lead to excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil cat-
egories; the lower half may contain words to describe oil energy conserving features. The center section identifies the
SAE oil viscosity grade.
Oil viscosity recommendations are as follows:
The use of a multi-grade lubricating oil has been found to improve oil consumption control and improve engine cranking
in cold temperatures while maintaining lubrication at high operating temperatures.
While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous table for oil vis-
cosity recommendations for extreme climates.
NOTICE:
Limited use of low viscosity oils, such as SAE 10W-30 may be used for easier starting and providing sufficient
oil flow at ambient temperatures below -5°C (+23°F). However, continuous use of low viscosity oils can
decrease engine life due to wear.
Special “break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the
“break-in” as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating
Oils Data Book for Automotive and Industrial Engines.” The data book may be ordered from the Engine Manufacturers
Association, 401 North Michigan Ave., Chicago, Il U.S.A. 60611. The telephone number is (312) 644-6610.
ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic engine oil API performance classification CF-4, CG-4, CF-4/SG
or CG-4/SH with adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.
NOTICE:
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can
decrease engine life due to factors such as corrosion, deposits and wear.
01-8 HM400-1L
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE

BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
Komatsu Engine Oil or engine oil meeting American Petroleum Institute (API) performance classification CF-4, CG-4, CF-4/
SG or CG-4/SH or MIL-L-2104D or E is recommended.
NOTICE:
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH oil is
not yet available.
FINAL DRIVE OIL SPECIFICATIONS
Komatsu Gear Lubricant or an equivalent multi-purpose gear lubricant meeting API GL-5 or MIL-L-2105C is recommended.
DRIVE AXLE OIL SPECIFICATIONS
For drive axle oil, use only the recommended oil as follows:
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL 424
Engine oil: SAE 30 API classification CD (May increase brake noise, but will not affect durability.)
DIESEL FUEL SPECIFICATIONS
WARNING
Never mix gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire hazard and, under
certain conditions, an explosion which could result in personal injury or death.
WARNING
Never remove the fuel tank filler cap or refill the fuel tank while the engine is running or when hot or when the
machine is indoors. Fumes are dangerous, a spark or flame could result in a fire or explosion.
NOTICE:
The precise tolerances of diesel fuel injection systems demand that the fuel be kept clean and free of contaminates
or water. Contaminates or water in the system can cause severe damage to both the injection pump and nozzles.
REMARK:
Below -12°C (+10°F) the paraffin in ASTM Grade No. 2-D diesel fuel will change to wax particles and clog the fuel
filters. For best results use Grade No. 1-D diesel fuel in cold weather.
For normal service above -10°C (+14°F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is
recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke.
At operating temperatures below -10°C (+14°F) or extended engine idling, use ASTM Grade No. 1-D diesel fuel. The use of
lighter fuels can reduce fuel economy.
HM400-1L 01-9
Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel. How-
ever, it is the supplier's responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud
point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt to provide adequate fuel system lubrication.
Optionally, the equivalent grades of recognized Federal Government specifications may be used; the latest revisions of VV-F-
800a.
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides recom-
mendations for selecting the engine coolant and maintaining the supplemental coolant additives (SCA).
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. The
coolant mixture must be drained and replaced at the specified service interval or every two years of operation, whichever
comes first.
WATER
Use water which has a low mineral content. Water used with antifreeze, coolant filters and inhibited water must meet the fol-
lowing standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the spec-
ified amount will cause scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale
deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water
supplies meet these standards, water samples can be tested by water treatment laboratories. Softened water that is prepared
using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
NOTICE:
Never use water alone in the cooling system because rust, scale deposits and corrosion will occur.
ANTIFREEZE
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and
by raising its boiling point.
In climates where the temperature is above -34°C (-30°F), use a coolant mixture that contains 50 percent antifreeze. Do not
use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 per-
cent antifreeze under any condition.
01-10 HM400-1L
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze concen-
trations between 68 and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be
used due to reduced heat transfer rates.
Ethylene glycol, low silicate antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
DO NOT use methanol or alcohol, which has an unacceptably low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corro-
sion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
NOTICE:
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against
freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak
additives will cause plugging problems in the cooling system.
WARNING
Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and gog-
gles and keep face away from the filler neck.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection
against freezing. An antifreeze concentration greater than 68% will adversely affect antifreeze protection and heat transfer
rates. Antifreeze concentrations between 68% and 100% actually have a higher freezing points than a 68% antifreeze concen-
tration as well as reduced heat transfer rates and should not be used.
REMARK:
Do not use a 100% antifreeze solution for freezing protection. This will cause severe corrosion in the cooling system
and if not detected will cause radiator and oil cooler core damage. Use a water/antifreeze solution as described in
the following table.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Approximate Freezing Point Percentage of Antifreeze Concentra- Specific Gravity at 16°C (60°F)
tion by Volume
0°C (+32°F) 0 1.000

-7°C (+20°F) 15 1.025
-12°C (+10°F) 25 1.040
-18°C (0°F) 33 1.053
-23°C (-10°F) 40 1.062
-29°C (-20°F) 45 1.070
-34°C (-30°F) 48 1.074
-40°C (-40°F) 53 1.080
-46°C (-50°F) 56 1.083
-51°C (-60°F) 59 1.088
-57°C (-70°F) 62 1.092
-62°C (-80°F) 65 1.095
-68°C (-90°F) 67 1.097
-69°C (-92°F) 68 1.098
HM400-1L 01-11
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor or supplemental coolant additive
(SCA), to protect the engine cooling system.
SUPPLEMENTAL COOLANT ADDITIVES
1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through normal oper-
ation. If the coolant additives in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks
and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which con-
tain these additives must be added to maintain corrosion protection.
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer and allow internal
engine damage.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best
coolant.
4. A corrosion inhibitor/conditioner is recommended to inhibit corrosion in the cooling system for the following reasons:
• Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration occurs.
• Provides engine protection in the following areas:
- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
- Aluminum cavitation/corrosion - Seal and gasket degradation
Maintenance of Supplemental Coolant Additives
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.
New machines are delivered with antifreeze protection. Service at a regular scheduled interval specified in the Operation and
Maintenance Manual.
Each time the coolant is drained and replaced, the coolant must be recharged with supplemental coolant additives. New cool-
ant can be correctly charged with coolant additives by using a replacement coolant filter and/or concentrate.
If coolant is added between drain intervals, additional coolant additives may be required.
Coolant Testing for Conditioner Concentration
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The SCA con-
centration must not fall below 1.0 unit per 3.8 liters (1 gal) or exceed 2 units per 3.8 liters (1 gal) of coolant. The only accurate
method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis. For this rea-
son, the coolant inhibitor should be maintained as shown in the Operation and Maintenance Manual.
NOTICE:
Inadequate concentration of the coolant additive can result in major corrosive damage to cooling system compo-
nents. Over-concentration can cause formation of gel that can cause restriction, plugging of passages and overheat-
ing.
01-12 HM400-1L
12
Replenishing Coolant Conditioner
Install a “precharge” coolant filter when the coolant is changed or a significant (more than 50%) coolant loss occurs.
When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 liters (1 US gal) of antifreeze.
NOTICE:
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test
kit available to measure concentration levels with mixed chemical solutions.
Supplemental Coolant Additive Maintenance Guide
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze
alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection
must be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S. gallon]
of coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each engine oil
and filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use the
appropriate replacement coolant filter listed in following tables. The coolant mixture must be drained and replaced as
defined under “General.”
The amount of a replacement inhibitor is determined by the length of the service interval and the cooling system capacity.
Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
HM400-1L 01-13
12 If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or
exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].
DCA4 UNIT GUIDE
Fleetguard Part No. DCA4 Units
DCA4 Coolant Filter

WF-2070 2
WF-2071 4
WF-2072 6
WF-2073 8
WF-2074 12
WF-2075 15
WF-2076 23
WF-2077 0
DCA4 Liquid
DCA60L 4 (1 pt)
DCA80L 1760 (55 gal)
DCA4 Powder
DCA95 20
DCA4 Precharge and Service Filters
System Capacity Precharge Filter Service Filter

(See NOTE 1) (See NOTE 3)
Liters Gallons
19-26 5-7 WF-2072 WF-2070

30-38 8-10 WF-2073 WF-2071
42-57 11-15 WF-2074 WF-2071
61-76 16-20 WF-2075 WF-2071
80-114 21-30 WF-2076 WF-2072
118-190 31-50 (See NOTE 2) WF-2073
NOTE 1 - After draining and replacing coolant, always precharge the cooling system to maintain the SCA concentration
between 1.0 and 2.0 units per 3.8 liters (1 US gal).
NOTICE:
When performing service which requires draining the cooling system, discard the coolant. Reusing coolant can
introduce contaminants or over-concentrated chemicals and result in premature failure of cooling system compo-
nents.
01-14 HM400-1L
12
NOTE 2 - To precharge cooling systems larger than 114 liters (30 gal) do the following:
• Install appropriate service filter listed in the above table based on cooling system capacity.
Example: 95 gal (360 liter) cooling system capacity

-15 Units (1) WF-2075 Filter
80 Units
• The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part
number DCA95, will provide a sufficient amount of SCA units (80) to precharge the example cooling system.
• Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal SCA concentration of 1.0 unit per 3.8 liters (1 US gal) of coolant in the system. Less than 0.5 units per 3.8
liters (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 liters (1 US gal) indicates an
over-concentrated coolant solution.
To check the SCA concentration level, use Coolant Test Kit CC-2626. Instructions are included with the test kit.
SCA Unit Concentration Guide
Number of Solution A Drops to Coolant Condition Action Required

Cause Color Change
0 - 10 Drops Extremely under-concentrated -less Initially charge the system to a mini-

than 0.4 SCA units per 3.8 liters (1 US mum of 1.0 SCA unit per 3.8 liters (1
gal) US gal).
11 - 16 Drops Marginally under-concentrated -0.45 Add SCA liquid units to maintain 1.0
to 0.8 SCA units per 3.8 liters (1 US SCA unit per 3.8 liters (1 US gal) mini-
gal) mum or change the DCA 4 coolant fil-
ter.
17 - 25 Drops Acceptable - 0.85 to 1.3 SCA units per None.

3.8 liters (1 US gal)
26 - 35 Drops Highly acceptable - 1.35 to 2.0 SCA None.

units per 3.8 liters (1 US gal)
36 - 55 Drops Marginally over-concentrated - 2.1 to Review maintenance practice.

3.3 SCA units per 3.8 liters (1 US gal)
Over 55 Drops Extremely over-concentrated Drain 50% of the coolant and replace
with water antifreeze mixture. Retest
the system for correct SCA unit concen-
tration.
HM400-1L 01-15
12
COOLING SYSTEM TEST KIT
The following cooling system test kit may be purchased from your Komatsu America International Company distributor.
This Fleetguard® coolant test kit, part number CC-2626 is used to

check the concentration of coolant additives in the cooling system.
1. Test strip bottles

2. Solution #1 bottle
3. Small plastic container
4. Large plastic cup
5. Syringe
01-16 HM400-1L
10 STRUCTURE AND FUNCTION
RADIATOR, OIL COOLER, AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
POWER TRAIN SKELETON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
LOCKING DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TRANSMISSION POWER PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
OIL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
FL - R CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
FH - 1ST CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
2ND - 3RD CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
CLUTCH OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
FORWARD 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
FORWARD 5TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
FORWARD 6TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
TRANSMISSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
ECMV (ELECTRONIC CONTROL MODULATION VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
ECMV FOR LOCK-UP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
DURING DIRECT TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
ECMV SPEED CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
ECMV OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
ECMV AND PROPORTIONAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
ECMV AND FILL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
ECMV OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
ECMV FOR DIFFERENTIAL LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
HM400-1L 10-1
STRUCTURE AND FUNCTION TABLE OF CONTENTS
TORQUE CONVERTER RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
LOCKING DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
TRAVELING IN A STRAIGHT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
WHEN DIFFERENTIAL LOCK IS ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-59
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
CENTER, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
UPPER PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
LOWER PORTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
APPLYING BRAKE WHEN UPPER VALVE FAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
APPLYING BRAKE WHEN LOWER VALVE FAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
WHEN ACTUATION IS BALANCED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
BRAKE RELEASED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
ACCUMULATOR CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-75
SLACK ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
CENTER, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
PROPORTIONAL REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
BRAKE SYSTEM TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
PARKING BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
SPRING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
PARKING BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
10-2 HM400-1L
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97
STRUCTURE AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
OSCILLATION HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
DUMP BODY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
HYDRAULIC TANK AND FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
FLOW AMP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
CONNECTION BETWEEN HAND PUMP AND SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
FUNCTION OF CENTER SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
HOIST VALVE AT HOLD POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
HOIST VALVE AT RAISE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
HOIST VALVE AT FLOAT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-118
HOIST VALVE AT LOWER POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
EPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
PILOT CHECK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
HOIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
STEERING, HOIST + PILOT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
TRANSMISSION + DIFFERENTIAL LOCK PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
BRAKE COOLING + BRAKE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
AUXILIARY STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
DIFFERENTIAL LOCK PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
CAB TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
RECEIVER DRYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
MACHINE MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
NETWORK DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
OPTION SETTING CONNECTOR DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
ADJUSTING MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
SELF-DIAGNOSTIC FUNCTION WHEN OPERATING STARTING SWITCH . . . . . . . . . . . . . . . 10-143
CHECK FUNCTION OF CENTRAL WARNING LAMP, ALARM BUZZER, MONITOR LAMPS AND
METERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
SERVICE METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
HM400-1L 10-3
OUTLINE OF SERVICE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
OPERATION METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
AUTOMATIC SHIFT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-149
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
GEARSHIFT LEVER POSITION AND AUTOMATIC GEARSHIFTING RANGE . . . . . . . . . . . . . . . . 10-154
GEARSHIFTING CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
AUTOMATIC GEARSHIFTING GRAPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-156
SHIFT HOLD FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
GEARSHIFTING TIME DELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
SAFETY FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
SELF-DIAGNOSTIC FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-158
AUTO AUXILIARY STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
SENSORS, SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
ACCELERATOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
ACCELERATOR SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
IDLE VALIDATION SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
ENGINE COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
BRAKE COOLING OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
STEERING OIL TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
TILT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-164
AIR CLEANER CLOGGING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
HYDRAULIC OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
BODY POSITIONER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
RETARDER CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
RETARDER CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
RETARDER CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
RETARDER CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-173
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HOIST CONTROL FUNCTION 10-175
HOIST CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-175
DIFFERENTIAL LOCK CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-177
BRAKE CONTROL SYSTEM (E-SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-179
BRAKE CONTROLLER (E-SPEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
BRAKE CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
BRAKE CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
HOIST CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
HOIST CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185
DIFFERENTIAL LOCK CONTROL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
10-4 HM400-1L
DUMP CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
DUMP CONTROL LEVER OPERATED TO FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
DUMP CONTROL LEVER FLOAT CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
DUMP CONTROL LEVER OPERATED TO LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
DUMP CONTROL LEVER OPERATED TO RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
DUMP CONTROL LEVER RAISE CANCELED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-191
PLM-HM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
SYSTEM STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
PRINCIPLE OF CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-193
ACCURATE CALCULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
GENERAL LOCATIONS OF LOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
LEFT FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-196
BASIC FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
KEY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
SERVICE CHECK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-207
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
ERROR CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-214
LOCAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217
HM400-1L 10-5
STRUCTURE AND FUNCTION RADIATOR, OIL COOLER, AFTERCOOLER
12
RADIATOR, OIL COOLER, AFTERCOOLER
1. Aftercooler SPECIFICATIONS
2. Coolant filler
3. Reservoir tank
Radiator
4. Upper tank
• Core type: CF4-5
5. Lower tank (torque converter, oil cooler)
• Total heat dissipating area: 67.93 m2
A. From thermostat Torque converter oil cooler
B. To water pump • Core type: PTO-LS
C. From rear brake • Total heat dissipating area: 4.0655 m2
D. To oil filter Steering oil cooler
E. From hoist valve • Core type: PTO-OL
F. To hydraulic tank • Total heat dissipating area: 0.896m2
G. From water pump
10-6 HM400-1L
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
POWER TRAIN SKELETON
LOCKING DIFFERENTIAL
HM400-1L 10-7
STRUCTURE AND FUNCTION POWER TRAIN SKELETON
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling and brake system pump (SAR(3)80+(1)25)
5. Torque converter, transmission, front brake cooling, differential lock control pump (SAR(3)100+(1)12+8)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SAR(3)100+100+(1)8)
9. Transmission
10. Oscillation hitch
11. Center drive shaft
12. Front differential
13. Front differential lock
14. Tire
15. Final drive (front)
16. Brake (front)
17. Rear drive shaft (front)
18. Center differential
19. Center differential lock
20. Tire
21. Final drive (center)
22. Brake (center)
23. Rear drive shaft (rear)
24. Rear differential
25. Rear differential lock
26. Tire
27. Final drive (rear)
28. Brake (rear)
29. Interaxle differential lock
10-8 HM400-1L
STRUCTURE AND FUNCTION OUTPUT SHAFT
OUTPUT SHAFT
1. Rubber cushion FUNCTION

2. Outer body
3. Flange The output shaft is installed to the engine flywheel and
4. Shaft absorbs the twisting vibration caused by changes in the
5. Coupling engine torque.
6. Inner body
7. Cover
HM400-1L 10-9
STRUCTURE AND FUNCTION OUTPUT SHAFT
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

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

6 Backlash at spline
0.099 – 0.202 0.4
Standard backlash (Dimension at
Deformation of Original dimension : Lo Replace
smallest width : L)
7 rubber cushion
75 67
External Without cranks
10-10 HM400-1L
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION HYDRAULIC
TORQUE CONVERTER AND TRANSMISSION HYDRAULIC PIPING
HM400-1L 10-11
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION HYDRAULIC
1. Engine
2. Torque converter
3. Transmission
4. Oil cooler (built into radiator)
5. Torque converter, transmission, brake cooling return filter
6. Rear brake cooling and brake system pump (SAR(3)80+25)
7. Brake system tank
8. Torque converter, transmission, front brake cooling, differential control pump (SAR(3)100+12+8) (SAR(3)100:E-SPEC)
9. Hydraulic tank
10-12 HM400-1L
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
A. Torque converter oil outlet port SPECIFICATIONS

B. Torque converter oil inlet port
C. To lockup clutch
Type:
• 3 element, 1-stage, 2-phase with modulation and
1. PTO gear (No. of teeth: 9)
lockup clutch
Lockup clutch:
• Multiple-disc clutch
• Hydraulic control (with modulation valve)
Stall torque ratio:
• 2.63
HM400-1L 10-13
1. Coupling 8. Starter shaft

2. Input shaft (No. of teeth: 108) 9. One way clutch
3. Housing 10. Starter
4. Drive case 11. Disc
5. Turbine 12. Piston
6. Race 13. Clutch housing
7. Pump 14. Retainer
10-14 HM400-1L
HM400-1L 10-15
Unit: mm
Standard size Tolerance Repair limit

Outside diameter of coupling and oil
1 0
seal sliding portion o 95 o 94.8
-0.087
Inside diameter of seal ring sliding por- +0.025
2 o 35 o 35.5
tion of input shaft sliding portion 0
3 o 420 o 420.5
tion of clutch housing 0
4 o 295 o 295.1
tion of clutch piston 0
5 o 135 o 135.5
tion of pump housing 0
6 o 70 o 70.5
tion of input shaft 0
-0.01
Wear of clutch housing Width 5 4.5
7 -0.04
seal ring Replace
Thickness 7 0 0.15 6.85
0
Wear of stator shaft seal Width 3.95
-0.1
3.55
8
ring
Thickness 5.5 0 0.1 4.95
Inside diameter of outer race one-way
9 o 127.844 0 0.013 o 127.874
clutch transmission surface
Outside diameter of inner race one-way
10 o 108.883 0 0.013 o 108.853
clutch transmission surface
Inside diameter of sliding portion of +0.015
11 o 109 o 109.08
bushing 0
0
12 Thickness of sliding portion bushing 5 4.5
-0.1
13 Thickness of clutch disc 5.4 0 0.1 4.8
Backlash between input shaft and PTO
14 0.17 – 0.45
gear
10-16 HM400-1L
TRANSMISSION POWER PATH
1. When lock-up clutch is disengaged

When the lock-up clutch is disengaged, drive case (1) and turbine
(2) are separated, and the torque converter functions as normal.
The power generated by the engine goes from the damper through
the drive shaft, is transmitted to coupling (3), input shaft (4) and
clutch housing (5), and rotates drive case (1) and pump (6) as one
unit.
The power from pump (6) uses oil as a medium, rotates turbine (2),
and is transmitted from turbine (2) to transmission output shaft (7).
2. When lock-up clutch is engaged

When the lock-up clutch is engaged, drive case (1) and turbine (2)
are engaged and form one unit. Stator (8) is rotated by the rotation
of pump (6) and turbine (2).
The power generated by the engine goes from the damper through
the drive shaft, is transmitted to coupling (3), input shaft (4) and
clutch housing (5), and rotates drive case (1) and pump (6) as one
unit.
In addition, drive case (1) and turbine (2) are engaged by the clutch,
so the power is transmitted directly from turbine (2) to transmission
output shaft (7) without using oil as a medium.
HM400-1L 10-17
OIL FLOW
The oil passes through the main relief valve, is adjusted by the torque
converter relief valve to a pressure less than the set pressure, and enters
inlet port A. It then passes through the oil passage in stator shaft (1) and
flows from between pump (2) and stator (3) to pump (2). The oil is
given centrifugal force by pump (2), enters turbine (4), and transmits the
energy of the oil to the turbine.
The oil from turbine (4) is sent to stator (3), and enters the pump again.
However, part of the oil passes between turbine (4) and stator (3) and is
sent from outlet port B to the oil cooler to be cooled. It is then used to
lubricate the transmission.
10-18 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1. Transmission case (front)

2. Transmission case (rear)
3. Oil filler pipe mount
4. Transmission control valve
5. Main relief, torque converter relief valve
HM400-1L 10-19
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
10-20 HM400-1L
HM400-1L 10-21
Tolerance
Standard Standard Clearance
size clearance limit
1 Clearance (F) between FL, R clutch bear- Shaft Hole
ing and case
o 160 0 0 -0.040 –0.025 –
-0.025 -0.040
2 Clearance (R) between FL, R clutch bear- o 160 0 0 -0.040 –0.025 –

ing and case -0.025 -0.040
3 Clearance (F) between FH, 1st clutch o 160 0 0 -0.040 –0.025 –

bearing and case -0.025 -0.040
4 Clearance (R) between FH, 1st clutch o 160 0 0 -0.040 –0.025 –

5 Clearance (F) between 2nd, 3rd clutch o 160 0 -0.012 -0.052 –0.013 –
6 Clearance (R) between 2nd, 3rd clutch o 160 0 -0.017 -0.052 –0.008 –
bearing and cage -0.025 -0.052
7 Clearance (F) between differential lock o 230 0 -0.014 -0.060 –0.016 –

clutch bearing and case -0.030 -0.060
8 Clearance (R) between differential lock o 230 0 -0.014 -0.060 –0.016 –

clutch bearing and case -0.030 -0.060
9 Clearance between front output bearing o 140 0 +0.018 -0.007 – –

and cage -0.018 -0.007 0.036
10 Clearance between front output bearing o 90 +0.035 0 -0.055 – –

and spacer +0.013 -0.020 -0.013

Width of input shaft seal ring groove
2.5 +0.18 2.7
+0.10
11
Width 2.4 0 0.05 2.2
Wear of input shaft seal
ring 0
Thickness 1.7 -0.10 1.5
Replace
Width of input shaft seal ring groove 3.2 +0.076 3.5
0
12 Width 3.1 0 0.05 2.8
Wear of input shaft seal
ring
Thickness 2.2 0 0.10 2.0
Inside diameter of seal ring sliding por- o 50 +0.050 o 50.1

tion of each shaft (rear) 0
Width of seal ring groove of each shaft 3.2 +0.076 3.5

(rear) 0
13
Width 3.1 0 2.8
Wear of seal ring of each -0.05
shaft (rear)
Thickness 2.05 0 0.10 1.8

tion of sleeve 0
Width of seal ring groove of sleeve 4.5 +0.05 5.0

+0.10
14
Width 4.5 -0.08 4.1
Wear of seal ring of -0.13
sleeve
Thickness 4.0 0 0.15 3.6

tion of front output shaft 0
Width of seal ring groove of front output 3.0 +0.15 3.3

shaft +0.10
15
Width 3.0 0 2.7
Wear of seal ring of front -0.10
output shaft
Thickness 3.5 0 0.10 3.35
16 Outside diameter of rear coupling oil seal o 120 0 o 119.8

sliding portion -0.087
10-22 HM400-1L
1. R idler gear (No. of teeth: 35)

2. Strainer
Unit: mm

Clearance between R idler gear size Shaft Hole clearance limit
3
bearing and case
0 -0.025 -0.050 – Replace
o 125 –
-0.018 -0.050 -0.007
Clearance between R idler gear +0.032 -0.036 -0.061 –
4 o 70 –
bearing and R idler gear +0.002 -0.061 -0.018
OUTLINE Clutch combination and reduction ratio

● The transmission is installed to the rear of the torque con- Reduction
verter. The power from the torque converter passes through Speed range Clutch used ratio
the transmission input shaft and enters the transmission. F1 FLx1st 6.061
● The transmission uses combinations of the FL, FH, and R F2 FHx1st 3.957
clutches and the three speed clutches to shift the power from F3 FLx2nd 2.574
the input shaft and selects a speed range from FORWARD 1st F4 FHx2nd 1.680
- 6th or REVERSE 1st - 2nd. This is then transmitted to the F5 FLx3rd 1.094
output shaft. F6 FHx3rd 0.714
● Shifting gears is done automatically by the automatic trans- R1 Rx1st 5.851
mission according to the changes in the engine speed. R2 Rx2nd 2.484
HM400-1L 10-23
FL - R CLUTCH
A. R Clutch oil port C. Lubricating oil port

B. FL clutch oil port D. Lock-up clutch oil port
1. Input shaft 5. FL, R cylinder

2. Idler gear (no. of teeth: 43) 6. R clutch
3. FL gear (no. of teeth: 33) 7. R gear (no. of teeth 25)
4. FL clutch
Unit: mm

Clearance (F) between FL, R shaft size Shaft Hole clearance limit
8
and bearing (F)
+0.071 0 -0.086 –
o 75 –
+0.061 -0.015 -0.061
Clearance (R) between FL, R shaft +0.071 0 -0.086 –
9 o 75 –
and bearing (R) +0.061 -0.015 -0.061
10 Thickness 2.0 0 0.05 1.8
Separator plate
Distortion – 0.05 0.15
Thickness 3.2 0 0.08 2.75 Replace
11 Friction plate
Load of wave spring
12 1274 N 114.7 N 1088 N
(height: 3.8 mm)
Thickness of FL clutch thrust
13 4 0 0.2 3.6
washer
Thickness of R clutch thrust
14 4 0 0.2 3.6
washer
15 End play of FL gear 0.14 – 0.86
16 End play of R gear 0.17 – 0.83
10-24 HM400-1L
FH - 1ST CLUTCH
A. 1st clutch oil port C. Lubricating oil port

B. FL clutch oil port
4. 1st clutch
1. FH gear (no. of teeth: 57) 5. 1st gear (no. of teeth: 30)
2. FH clutch 6. Idler gear (no. of teeth 49)
3. FH, 1st clutch, idler gear (no. of teeth: 67) 7. Upper shaft
Unit: mm

Clearance (F) between FH, 1st size Shaft Hole clearance limit
8
shaft and bearing
+0.071 0 -0.086 –
o 75 –
+0.051 -0.015 -0.051
Clearance (R) between FH, 1st +0.071 0 -0.086 –
9 o 75 –
shaft and bearing +0.051 -0.015 -0.051
10 Thickness 2.0 0 0.05 1.8
Separator plate
11 Friction plate
Load of wave spring
12 1274 N 114.7 N 1088 N
(height: 3.8 mm)
Thickness of FH clutch thrust
13 4 0 0.2 3.6
washer
Thickness of 1st clutch thrust
14 4 0 0.2 3.6
washer
15 End play of FH gear 0.17 – 0.83
16 End play of 1st gear 0.15 – 0.85
HM400-1L 10-25
2ND - 3RD CLUTCH
A. 2nd clutch oil port C. Lubricating oil port

B. 3rd clutch oil port
1. 3rd gear (no. of teeth: 25) 4. 2nd clutch

2. 3rd clutch 5. 2nd gear (no. of teeth: 43)
3. 2nd, 3rd cylinder, idler gear (no. of teeth: 62) 6. Idler gear (no. of teeth 54)
7. Lower shaft
Unit: mm

Clearance (F) between 2nd, 3rd size Shaft Hole clearance limit
8
shaft and bearing
+0.071 0 -0.086 –
o 75 –
+0.051 -0.015 -0.051
Clearance (R) between 2nd, 3rd +0.071 0 -0.086 –
9 o 75 –
shaft and bearing +0.051 -0.015 -0.051
10 Thickness 2.0 0 0.05 1.8
Separator plate
11 Friction plate
Load of wave spring
12 1274 N 114.7 N 1088 N
(height: 3.8 mm)
Thickness of 3rd clutch thrust
13 4 0 0.2 3.6
washer
Thickness of 2nd clutch thrust
14 4 0 0.2 3.6
washer
15 End play of 3rd gear 0.15 – 0.85
16 End play of 2nd gear 0.15 – 0.85
10-26 HM400-1L
DIFFERENTIAL LOCK
A. Lubricating oil port
1. Front output shaft 6. Planet gear (no. of teeth: 20)

2. Clutch hub 7. Ring gear (no. of teeth: 80)
3. Housing 8. Carrier
4. Differential lock clutch 9. Output gear (no. of teeth: 78)
5. Sun gear (no. of teeth: 40) 10. Rear output shaft
HM400-1L 10-27

Clearance between housing and size Shaft Hole clearance limit
11
bearing
+0.040 0 -0.065 –
o 170 –
+0.015 -0.025 -0.015
Clearance between output gear +0.065 0 -0.090 –
12 o 170 –
and bearing +0.040 -0.025 -0.040
Clearance between housing and 0 -0.012 -0.052 –
13 o 130 –
bearing -0.018 -0.052 -0.006
Clearance between front output +0.012 0 -0.027 –
14 o 75 –
shaft and bearing -0.007 -0.015 -0.007
Clearance (F) between output gear 0 -0.050 -0.090 –
15 o 150 –
and bearing -0.020 -0.090 -0.030
Clearance (R) between output gear 0 -0.028 -0.068 –
16 o 150 –
and bearing -0.020 -0.068 -0.008
Clearance between front output +0.028 0 -0.048 –
17 o 100 –
shaft and bearing +0.013 -0.020 -0.013 Replace
18 Thickness 2.0 0 0.05 1.8
Separator plate
Thickness 3.2 0 0.10 2.75
19 Friction plate
Load of wave spring
20 1480 N 440 N 1255 N
(height: 3.2 mm)
Inside diameter of seal ring sliding +0.030
o 70 70.1
portion of carrier 0
Width of seal ring groove of front
2.1 0 0.05 2.3
21 output shaft
0
Wear of seal ring of Width 1.95 1.76
-0.1
front output shaft
Thickness 1.85 0 0.1 1.67
10-28 HM400-1L
CLUTCH OPERATIONS
Clutch engaged (fixed)
● The oil sent from the transmission valve passes through the oil pas-
sage inside shaft (1), reaches the back face of piston (6) and acts on
piston (6).
● When piston (6) is actuated, separator plate (2) and friction plate (3)
are pressed together, shaft (1) and clutch gear (4) form one unit, and
the power is transmitted.
● When this happens, the oil is drained from oil drain hole (5), but the
drain amount is less than the amount of oil supplied, so there is no
influence on the actuation of the clutch.
★ Oil drain hole (5) forms part of the structure of only the 2nd, 3rd,
and differential lock clutches.
Clutch disengaged (free)
● The oil sent from the transmission valve is shut off, so the pressure
of the oil acting on the back face of piston (6) goes down.
● Piston (6) is returned to its original position by wave spring (7), and
shaft (1) and clutch gear (4) are separated.
● When the clutch is disengaged, centrifugal force is used to drain the
oil at the back face of the piston through oil drain hole (5). This acts
to prevent the clutch from being partially applied.
HM400-1L 10-29
FORWARD 1ST
OPERATION
● When FORWARD 1st, FL clutch (3) and 1st clutch (11) are engaged, the power from the torque converter is transmitted to
input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FL clutch (3) and 1st clutch (11) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) through FL clutch (3), goes to FL gear (5), and is
then transmitted to FH, 1st cylinder gear (8).
● 1st clutch (11) is engaged, so the power transmitted to FH, 1st cylinder gear (8) passes through 1st clutch (11), and goes
from 1st gear (12) to 2nd, 3rd cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmit-
ted to differential lock carrier (21).
● When the differential lock switch is OFF, the front output force passes from planet gear (25) through sun gear (26), and is
transmitted to front output shaft (28). The rear output force passes from planet gear (25) through ring gear (27), and is
transmitted to rear output shaft (29).
★ If the differential lock is ON, see FORWARD 2ND.
10-30 HM400-1L
FORWARD 2ND
OPERATION
● When FORWARD 2nd, FH clutch (10) and 1st clutch (11) are engaged, the power from the torque converter is transmitted
to input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FH clutch (10) and 1st clutch (11) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) to idler gear (2) and goes to FH gear (9), passes
through FH clutch (10), and is then transmitted to FH, 1st cylinder gear (8).
● When the differential lock switch is ON, the front output force passes from housing (22) through differential lock clutch
(23) and clutch hub (24), and is transmitted to front output shaft (28). The rear output force passes from planet gear (25)
through ring gear (27), and is transmitted to rear output shaft (29).
★ If the differential lock is OFF, see FORWARD 1ST.
HM400-1L 10-31
FORWARD 3RD
OPERATION
● When FORWARD 3rd, FL clutch (3) and 2nd clutch (17) are engaged, the power from the torque converter is transmitted
● FL clutch (3) and 2nd clutch (17) hold each clutch disc in position with the oil pressure applied to the piston.
then transmitted through FH, 1st cylinder gear (8) and idler gear (13), and goes to 2nd gear (15).
● 2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd clutch (17), and goes to 2nd, 3rd
cylinder gear (14). It then goes through idler gear (19) and output gear (20), and is transmitted to differential lock carrier
(21).
★ The diagram above shows the situation when the differential lock is OFF.
★ For details of the actuation when the differential lock is OFF, see FORWARD 1ST; for details of the actuation when the
differential lock is ON, see FORWARD 2ND.
10-32 HM400-1L
FORWARD 4TH
OPERATION
● When FORWARD 4th, FH clutch (10) and 2nd clutch (17) are engaged, the power from the torque converter is transmit-
ted to input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● FH clutch (10) and 2nd clutch (17) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2) and FH gear (9), passes
through FH clutch (10), and is then transmitted through FH, 1st cylinder gear (8) and idler gear (13), and is transmitted to
2nd gear (15).
● 2nd clutch (17) is engaged, so the power transmitted to 2nd gear (15) passes through 2nd clutch (17), and goes to 2nd, 3rd
(21).
★ The diagram above shows the situation when the differential lock is ON.
HM400-1L 10-33
FORWARD 5TH
OPERATION
● When FORWARD 5th, FL clutch (3) and 3rd clutch (18) are engaged, the power from the torque converter is transmitted
● FL clutch (3) and 3rd clutch (18) hold each clutch disc in position with the oil pressure applied to the piston.
then transmitted through FH, 1st cylinder gear (8) to 3rd gear (16).
● 3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch (18), and goes to 2nd, 3rd
(21).
10-34 HM400-1L
FORWARD 6TH
OPERATION
● When FORWARD 6th, FH clutch (10) and 3rd clutch (18) are engaged, the power from the torque converter is transmitted
● FH clutch (10) and 3rd clutch (18) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1), goes to idler gear (2) and FH gear (9), passes
through FH clutch (10), and is then transmitted through FH, 1st cylinder gear (8) to 3rd gear (16).
● 3rd clutch (18) is engaged, so the power transmitted to 3rd gear (16) passes through 3rd clutch (18), and goes to 2nd, 3rd
(21).
★ The diagram above shows the situation when the differential lock is ON.
HM400-1L 10-35
REVERSE 1ST
OPERATION
● When REVERSE 1st, R clutch (4) and 1st clutch (11) are engaged, the power from the torque converter is transmitted to
input shaft (1), and then transmitted to front and rear output shafts (28) and (29).
● R clutch (4) and 1st clutch (11) hold each clutch disc in position with the oil pressure applied to the piston.
● The power from the torque converter is transmitted from input shaft (1) through R clutch (4), goes to R gear (6), is rotated
in the opposite direction by R idler gear (7), passes through idler gear (13), and is then transmitted to FH, 1st cylinder gear
(8).
10-36 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION VALVE
TRANSMISSION VALVE
A. Lock-up clutch oil pressure detection port 1. ECMV (for lock-up clutch)
B. 2nd clutch oil pressure detection port 2. ECMV (for 2nd clutch)
C. 3rd clutch oil pressure detection port 3. ECMV (for 3rd clutch)
D. R clutch oil pressure detection port 4. ECMV (for R clutch)
E. FL clutch oil pressure detection port 5. ECMV (for FL clutch)
F. 1st clutch oil pressure detection port 6. ECMV (for 1st clutch)
G. FH clutch oil pressure detection port 7. ECMV (for FH clutch)
H. Differential lock clutch oil pressure detection port 8. ECMV (for differential lock clutch)
9. Seat
10. Last chance filter
HM400-1L 10-37
STRUCTURE AND FUNCTION TRANSMISSION VALVE
ECMV clutch operation table
ECMV
FL FH R 1st 2nd 3rd

Speed range
F1 w w
F2 w w
F3 w w
F4 w w
F5 w w
F6 w w
R1 w w
R2 w w
N
10-38 HM400-1L
STRUCTURE AND FUNCTION ECMV (ELECTRONIC CONTROL MODULATION VALVE)
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
A. To clutch 1. Connector for fill switch

P. From pump 2. Connector for proportional solenoid
T. Drain 3. Oil pressure detection valve
Dr. Drain 4. Fill switch
P1. Clutch oil pressure detection port 5. Proportional solenoid
P2. Pilot oil pressure detection port 6. Pressure control valve
HM400-1L 10-39
ECMV FOR LOCK-UP CLUTCH

OUTLINE
● This valve acts to set the lock-up clutch oil pressure to the set pres-
sure, and also to switch the lock-up clutch. It forms a modulation
wave pattern, so the lock-up clutch is engaged smoothly to reduce
the shock when shifting gear. In addition, it prevents generation of
peak torque in the power train. As a result, it provides a comfort-
able ride for the operator and greatly increases the durability of the
power train.
OPERATION
During torque converter travel
● When the transmission is in torque converter travel, no current

flows to proportional solenoid (1).
● Pressure control valve (3) drains the oil at clutch port A through
drain port Dr and cancels the lock-up clutch. When this happens,
there is no oil pressure acting on oil pressure detection valve (4), so
fill switch (6) is OFF.
10-40 HM400-1L
DURING DIRECT TRAVEL

FROM TORQUE CONVERTER TRAVEL TO DIRECT TRAVEL
1. When filling
When the transmission is in direct travel (lock-up), if electric cur-
rent is applied to proportional solenoid (1) by the electric signal, a
hydraulic force balancing with the force of the solenoid acts on
chamber B, and pressure control valve spool (3) moves 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, fill switch (6) is turned ON.
2. Adjusting pressure
When electric current flows to proportional solenoid (1), the sole-
noid generates a propulsion force proportional to the current. The
pressure is adjusted so that the total of this propulsion force of the
solenoid, the propulsion force of the oil pressure at the clutch port,
and the reaction force of pressure control valve spring (2) is bal-
anced. To reduce the shock when shifting gear, the oil pressure of
the lock-up clutch is temporarily lowered during the gearshifting
operation. The oil pressure at this point is an oil pressure which bal-
ances the pushing force of the lock-up piston and the pressure
inside the torque converter.
HM400-1L 10-41
ECMV SPEED CLUTCH

ECMV OUTLINE
The ECMV (Electronic Control Modulation Valve) consists of two
components: the pressure control valve and the fill switch.
Pressure control valve
The proportional solenoid receives the flow of electricity sent from the
transmission controller, and the pressure control valve converts this into
hydraulic pressure.
Fill switch
This detects when oil has filled the clutch. It has the following func-
tions.
1. When the clutch is filled with oil, it sends a signal (fill signal) to the
controller to inform the controller that the filling is completed.
2. While oil pressure is applied to the clutch, it outputs a signal (fill

signal) to the controller to inform the controller of the existence of
the oil pressure.
A range: Before gear shifting (drained)
B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
ECMV AND PROPORTIONAL SOLENOID

There is one proportional solenoid installed to each ECMV. It generates
propulsion as shown in the diagram at the right according to the com-
mand current from the controller.
The propulsion generated by the proportional solenoid acts on the pres-

sure control valve spool and generates oil pressure as shown in the dia-
gram below. In this way, the command current is controlled and the
propulsion force varies to actuate the pressure control valve and control
the oil flow and oil pressure.
ECMV AND FILL SWITCH

There is one fill switch installed to each ECMV. When the filling of the
clutch is completed, the fill switch is turned on by the clutch pressure.
With this signal, the oil pressure starts to build up.
10-42 HM400-1L
ECMV OPERATION
The ECMV is controlled by the command current from the transmission
controller to the proportional solenoid and the fill switch output signal.
The relationship between the ECMV proportional solenoid command
current and the clutch input pressure and fill switch output signal is as
shown in the diagram below.
A range: Before gear shifting (drained)

B range: Filling starts (trigger issued)
C range: Filling completed
D range: Regulation
E range: Filling
1. When shifting gears (during draining) (Range A in graph)

When no current is flowing to proportional solenoid (1), pressure
control valve spool (3) drains the oil at clutch port A through drain
port Dr. When this happens, there is no hydraulic force acting on
pressure detection valve (4), so fill switch (6) is turned OFF.
HM400-1L 10-43
2. When filling (when trigger command is input to pressure control
valve) (Ranges B and C in graph)
When there is no oil inside the clutch, if electric current is applied
to proportional solenoid (1), a hydraulic force balancing the force
of the solenoid acts on chamber B, and pressure control valve spool
(3) moves 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, fill switch (6) is turned ON.
3. Adjusting pressure (Range D in graph)

When electric current flows to proportional solenoid (1), the sole-
noid generates a propulsion force proportional to the current. The
pressure is adjusted so that the total of this propulsion force of the
solenoid, the propulsion force of the oil pressure at the clutch port,
and the reaction force of pressure control valve spring (2) is bal-
anced.
10-44 HM400-1L
ECMV FOR DIFFERENTIAL LOCK

Operation
1. When differential lock switch is turned ON ➔ OFF

When the differential lock switch is turned OFF, there is no electric
current flowing from the controller to proportional solenoid (1) of
the ECMV, so the oil at clutch port A passes through drain port Dr
and is drained. As a result, the force of the oil pressure at clutch
port A goes down and piston (2) is returned to its original position
by wave spring (5). Carrier (6) and front output shaft (7) are sepa-
rated, and the power is transmitted by the planetary gear. The pro-
portion of the torque at this point is as follows:
Front 1: Rear 2
2. When differential lock switch is turned OFF ➔ ON

When the differential lock switch is turned ON, and electric signal
is sent from the controller to proportional solenoid (1) of the
ECMV, and oil starts to fill clutch port A. As a result, piston (2) is
actuated, presses separator plate (3) and friction plate (4) together,
so carrier (6) and front output shaft (7) form one unit and transmit
the power.
The proportion of the torque at this point is as follows:

Front 1: Rear 1
HM400-1L 10-45
STRUCTURE AND FUNCTION MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A. Drain (torque converter relief) 1. Body

B. Drain 2. Piston
C. From pump 3. Torque converter relief valve
D. Drain 4. Piston
E. To torque converter 5. Main relief valve
P1. Main relief oil pressure detection port
P2. Torque converter relief oil pressure detection port
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
6
valve and valve body
o 28 -0.035 +0.013 0.035 – 0.078
-0.045 0 0.058
Clearance between torque con- -0.035 +0.013 0.035 –
7 verter relief valve and valve body o 22 -0.045 0 0.058 0.078
Standard size Repair limit Replace
8 Main relief valve spring (outside) Free length Installed Installed Free length Installed
length load load
108 79.5 275 N 104.8 261 N
9 Main relief valve spring (inside) 108 79.5 326 N 104.8 309 N
10 Torque converter relief valve 50 41 173 N 48.5 164 kN

spring
10-46 HM400-1L
OUTLINE
TORQUE CONVERTER RELIEF VALVE
The torque converter relief valve protects the torque converter from
abnormally high pressure. It is installed in the torque converter inlet port
circuit to hold the oil pressure in the torque converter inlet port circuit
below the set pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(Cracking pressure)
MAIN RELIEF VALVE

The main relief valve holds the oil pressure in the transmission and
brake at the set pressure.
Set pressure: 2.62 MPa {26.7 kg/cm2}
(Engine at rated speed)
OPERATION
Torque converter relief valve operation
● The oil relieved by the main relief valve flows from port C into the
torque converter, and at the same time, passes through orifice b of
spool (2) and enters chamber D. When the circuit leading to the
torque converter becomes filled with oil, the oil pressure starts to
rise.
● As the oil pressure going to the torque converter rises, the oil enter-
ing chamber D pushes piston (9). The reaction force compresses
valve spring (3) and moves spool (2) to the right to open the circuit
between port C and port E. When this happens, the oil at port C is
relieved to port E and drains to the oil tank. The oil pressure at port
C at this point is 0.91 MPa {9.31 kg/cm2} (cracking pressure).
Main relief valve operation
● The oil from the hydraulic pump passes through the filter and enters
port A of the relief valve. It then passes through orifice a of spool
(6) and enters chamber B. When the oil from the pump fills the cir-
cuit, the oil pressure starts to rise.
HM400-1L 10-47
As the oil pressure in the circuit rises, the oil entering chamber B pushes
piston (4). The reaction force compresses valve spring (7) and moves
spool (6) to the left to open the circuit between port A and port C. When
this happens, the oil at port A is relieved to port C and flows from port C
to the torque converter. The oil pressure at port A at this point is 2.62
MPa {26.7 kg/cm2} (engine at rated speed).
10-48 HM400-1L
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
1. Drive shaft (right) OUTLINE

2. Front drive shaft
3. Drive shaft (left)
● The power from the engine goes from the output
4. Center drive shaft
shaft through front drive shaft (2), the transmission,
5. Rear drive shaft (front)
and the front axle, and is transmitted by left and
6. Rear drive shaft (rear)
right drive shafts (1) and (3). The rest of the power
passes through center drive shaft (4) and the oscilla-
tion 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 trans-
mitted 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.
HM400-1L 10-49
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT
1. Drive shaft
2. Front differential
3. Brake
4. Final drive
10-50 HM400-1L
CENTER
1. Center differential
2. Center axle
3. Brake
4. Final drive
5. Drain plug
HM400-1L 10-51
REAR
1. Drain plug
2. Rear differential
3. Rear axle
4. Brake
5. Final drive
10-52 HM400-1L
STRUCTURE AND FUNCTION LOCKING DIFFERENTIAL
LOCKING DIFFERENTIAL
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
HM400-1L 10-53
Unit: mm

Wear of coupling oil seal contact
9 0
surface 95 94.9 Repair or
-0.087
replace
Wear of coupling oil seal contact 0
10 110 109.9
surface -0.087
Thickness of side gear thrust
11 4 0 0.05 3.5
washer
Replace
12 Thickness of disc 3.5 0 0.1 3.1
13 Thickness of plate 2.1 0 0.1 1.9
Backlash between bevel gear and
14 0.42 – 0.65 (in circumferential direction at outside diameter) Adjust
pinion
10-54 HM400-1L
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)
HM400-1L 10-55
Unit: mm

Wear of coupling oil seal contact Repair or
9 0
surface 95 94.9 replace
-0.087
10 4 0 0.05 3.5
washer
Replace
13 0.42 – 0.65 (in circumferential direction at outside diameter) Adjust
pinion
10-56 HM400-1L
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)
HM400-1L 10-57
Unit: mm

Wear of coupling oil seal contact Repair or
9 0
surface 90 89.9 replace
-0.087
10 4 0 0.05 3.5
washer
Replace
13 0.42 – 0.65 Adjust
pinion
OPERATION
● The power from the engine is transmitted through the output shaft,
front drive shaft, torque converter, and transmission to each axle.
● Inside the axle, the power is transmitted from pinion gear (5) to
bevel gear (1), is converted and sent at 90°, has its speed reduced,
and is transmitted through pinion gear (6) and side 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
TRAVELING IN A STRAIGHT LINE

● When the machine is traveling in a straight line, the speed that the
wheels turn on the left and right sides is the same, so pinion gear (6)
inside the differential assembly does not turn, and the power of dif-
ferential case (2) is transmitted equally through side gear (3) to the
left and right shafts.
TURNING
● When the machine is turned, the speed that the wheels turn on the
left and right sides is different, so pinion gear (6) and side gear (3)
inside the differential rotate according to the difference in the turn-
ing speed on the left and right sides, and transmit the power of dif-
ferential case (2) to the left and right shafts.
10-58 HM400-1L
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 the wheel on the side where there is little
load resistance turns, and as a result, the power cannot be transmit-
ted. In such a case, it becomes impossible to travel, so differential
lock (7) is actuated to stop the rotation of pinion gear (4) and trans-
mit the power equally to left and right axle shafts (2).
HM400-1L 10-59
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
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
10-60 HM400-1L
Unit: mm
Backlash between planet gear and

8 0.19 – 0.43
sun gear
Replace
9 0.19 – 0.53
ring gear
10 Curvature of drive shaft Repair limit: 0.7TIR Repair or replace
11 Thickness of spacer Replace
12 0 0.1 11.5
Wear of outside diameter of por-
0
12 tion of axle tube inserted into 180 179.8
-0.025
bearing
Correct
0
-0.025
bearing

Clearance between shaft (outside size Shaft Hole clearance limit
14 Replace
diameter) and bushing
0 +0.337 0.251 –
65 0.4
-0.013 +0.251 0.350
HM400-1L 10-61
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
sun gear
Replace
9 0.19 – 0.53
ring gear
10 Curvature of drive shaft Repair limit: 1.5TIR Repair or replace
11 Thickness of spacer Replace
26 0 0.1 11.5
0
-0.025
bearing
Correct
0
-0.025
bearing
10-62 HM400-1L
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 trans-
mitted 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.
HM400-1L 10-63
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Joint shaft
6. Steering valve
10-64 HM400-1L
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
HM400-1L 10-65
STRUCTURE AND FUNCTION BRAKE PIPING
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
10-66 HM400-1L
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
1. Pilot piston A. To center, rear brake

2. Rod B. To front brake
3. Lower cylinder C. To brake system tank
4. Spool D. From front accumulator
5. Upper cylinder E. From rear accumulator
6. Spool
HM400-1L 10-67
OPERATION
UPPER PORTION
● When brake pedal (1) is depressed, the operating force is transmit-
ted to spool (3) through rod (2) and spring (4). When spool (3) goes
down, drain port a is closed, and the oil from the pump and accumu-
lator flows from port A to port C and actuates the center and rear
brake cylinders.
●
LOWER PORTION
● When brake pedal (1) is depressed, the operating force is transmit-
ted 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 hap-
pens, drain port b is closed, and the oil from the pump and accumu-
lator flows from port B to port D and actuates the front brake
cylinders.
APPLYING BRAKE WHEN UPPER VALVE FAILS

Even if there oil leakage in the upper piping, spool (5) is moved down
mechanically when pedal (1) is depressed, and the lower portion is actu-
ated normally. The upper brake is not actuated.
APPLYING BRAKE WHEN LOWER VALVE FAILS

Even if there is oil leakage in the lower piping, the upper portion is actu-
ated normally.
WHEN ACTUATION IS BALANCED

Upper portion
● When oil fills the center and rear brake cylinders and the pressure
between port A and port C becomes 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 between port A and port C. When
this happens, drain port a stays closed, so the oil entering the brake
cylinder is held and the brake remains applied.
10-68 HM400-1L
Lower portion
● When spool (3) in the upper portion moves up and the circuit
between port A and port C is shut off, oil also fills the front brake
cylinder at the same time, so the pressure in the circuit between port
B and port D rises. The oil entering port J from orifice f of spool (5)
pushes up spool (5) by the same amount that spool (3) moves, and
shuts off port B and port D. Drain port b is closed, so the oil entering
the 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, and the pressure in the space in the
lower portion is balanced with the pressure in the space in the upper
portion. When spools (3) and (5) move to the end of their stroke, the
circuits between ports A and C and between ports B and D are fully
opened, so the pressure in the space in the upper and lower portions
and the 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.
HM400-1L 10-69
BRAKE RELEASED
Upper portion
When pedal (1) is released and the operating force is removed from the
top of the spool, the back pressure from the brake cylinder and the force
of the spool return spring move spool (3) up. Drain port a is opened and
the oil from the brake cylinder flows to the brake system tank return cir-
cuit to release the center and rear brakes.
Lower portion
When the pedal is released, spool (3) in the upper portion moves up. At
the same time, the back pressure from the brake cylinder and the force of
the spool return spring move spool (5) up. Drain port b is opened and the
oil from the brake cylinder flows to the brake system tank return circuit
to release the front brake.
10-70 HM400-1L
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
ACCUMULATOR CHARGE VALVE
ACC To accumulator FUNCTION

P From hydraulic pump
PP To accumulator
● The accumulator charge valve is actuated to main-
T To brake tank
tain the oil pressure from the pump at the specified
pressure and to store it in the accumulator.
● When the oil pressure reaches the specified pres-
sure, the oil from the pump is connected to the drain
circuit to reduce the load of the pump.
HM400-1L 10-71
1. Main relief valve (R3) 4. Relief valve (H1)

2. Valve body 5. Filter
3. Relief valve (R1) 6. Filter
10-72 HM400-1L
OPERATION
1. When oil is not supplied to accumulator
(cut-out condition)
● The pressure at port B is higher than the set pressure of the relief
valve (R1), so piston (8) is forcibly pushed up by the oil pressure at
port B. Poppet (6) is opened, so 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 oil from the pump enters port P, pushes spool
(15) to the right at a low pressure equivalent to the load on spring
(14). It also passes through orifices (17), (18) and (16), and flows to
the brake oil tank.
2. When oil is supplied to accumulator
A. (cut-in condition)
● When the pressure at port B is lower than the set pressure of the
relief valve (R1), piston (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought into tight contact, and
port C and port T are shut off.
● The spring chamber at the right end of spool (15) is also shut
off from port T, so the pressure rises, and the pressure at port P
also rises in the same way.
● When the pressure at port P goes above the pressure at port B
(accumulator pressure), the supply of oil to the accumulator
starts immediately. In this case, it is decided by the size (area)
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.
HM400-1L 10-73
B. (When cut-out pressure is reached)
● When the pressure at port B (accumulator pressure) reaches the
set pressure of the relief valve (R1), poppet (6) separates from
valve seat (7), so an oil flow is generated and the circuit is
relieved.
● When the circuit is relieved, a pressure difference 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 circuited.
● 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.
3. Main relief valve (R3)

● If the pressure at port P (pump pressure) goes above the set pressure
of the relief valve (R3), the oil from the pump pushes spring (3).
Ball (11) is pushed up and the oil flows to the brake oil tank circuit,
so this set the maximum pressure in the brake circuit and protects
the circuit.
10-74 HM400-1L
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
1. Valve FUNCTION
2. Top cover
3. Cylinder
● The accumulator is installed between the accumula-
4. Piston
tor charge valve and the brake valve. It is charged
with nitrogen gas between cylinder (3) and free pis-
ton (4), and uses the compressibility of the gas to
absorb the pulse of the hydraulic pump or to main-
tain the braking force and to make it possible to
operate the machine if the engine should stop.
SPECIFICATIONS
Gas used: Nitrogen gas
Charge amount: 4,000 cc
Charging pressure: 4.4 0 0.15MPa
HM400-1L 10-75
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder A. Outlet port

2. Cylinder B. Inlet port
3. Check valve
4. Spring
5. Piston

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

-0.076 0 0.150 Replace
Standard size Repair limit
Installed Installed Installed
Front Free length length load Free length load
7 Slack adjuster spring
230 88 118 N – –
Center rear 198 38 43.2 N – –
10-76 HM400-1L
FUNCTION
The slack adjuster is installed in the brake oil line from the brake valve
to the brake piston. It acts to keep the clearance between the brake piston
and discs constant even when the brake discs are worn. In this way 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 returned by the distance
of stoke S (full stroke). When the brake pedal is depressed, the oil
discharged from the brake valve flows from port P of the slack
adjuster and is divided to left and right cylinders (2), where it moves
piston (4) by stroke S to the left and right.
● When this is done, brake piston (7) moves by a distance of stroke S.
In this condition, the closer the clearance between the brake piston
and disc is to 0, the greater the braking force becomes.
● If the brake pedal is depressed further, and the oil pressure dis-
charged from the brake valve goes above to set pressure, check
valve (3) opens and the pressure is applied to port C to act as the
braking force. Therefore, when the brake is applied, the time lag is a
fixed value.
● If the brake pedal is depressed further, and the oil pressure dis-
charged from the brake valve goes above to set pressure, check
valve (3) opens and the pressure is applied to port C to act as the
braking force. Therefore, when the brake is applied, the time lag is
a fixed value.
HM400-1L 10-77
2. When brake pedal is released
● When the brake is released, piston (4) is returned by brake return
spring (8) by an amount equivalent to the oil for the stroke S, and
the brake is released. 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 regard-
less of the wear of the brake disc.
10-78 HM400-1L
STRUCTURE AND FUNCTION BRAKE
BRAKE
FRONT
1. Stud pin
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
HM400-1L 10-79
Unit: mm
Backlash between outer gear and Standard size Repair limit
1
plate 0.52 – 0.90 1.5
Backlash between hub gear and
2 0.52 – 0.90 1.5
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 fric-
7 Max 0.50 0.7
tion surface
Assemble thickness of plate and Standard warping Repair limit
8
disc 56.4 51.4
9 Retainer oil seal contact surface 430 0 – -0.155 Correct or replace
CENTER, REAR
10-80 HM400-1L
1. Stud pin
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
HM400-1L 10-81
Unit: mm
Backlash between outer gear and Standard size Repair limit
1
plate 0.52 – 0.90 1.5
Backlash between hub gear and
2 0.52 – 0.90 1.5
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 fric-
7 Max 0.50 0.7
tion surface
Assemble thickness of plate and Standard warping Repair limit
8
disc 56.4 51.4
9 Retainer oil seal contact surface 430 0 – -0.155 Correct or replace
10-82 HM400-1L
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 presses 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 reduces 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 releases the
brake.
HM400-1L 10-83
STRUCTURE AND FUNCTION PROPORTIONAL REDUCING VALVE
PROPORTIONAL REDUCING VALVE
1. Filter FUNCTION
2. Connector
3. Solenoid assembly
The proportional reducing valve is a valve used for
retarder control. It is installed between the brake valve
A. To slack adjuster
and the slack adjuster in the brake circuit.
P. To brake valve (inlet)
T. To brake system tank
It varies the discharge pressure of the pressure oil in
accordance with the turning angle of the retarder control
lever, so the retarder control can be carried out as
desired.
10-84 HM400-1L
STRUCTURE AND FUNCTION BRAKE SYSTEM TANK
BRAKE SYSTEM TANK
1. Boss
2. Return
3. Suction tube
A. To hydraulic pump
B. From accumulator charge valve
C. Oil filler port
D. Drain port
HM400-1L 10-85
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
1. Spring cylinder FUNCTION

2. Parking brake disc
● The parking brake is a disc type and is installed to
the front axle.
● 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 front dif-
ferential. The disc is installed to the differential
yoke and rotates together with the coupling.
10-86 HM400-1L
STRUCTURE AND FUNCTION PARKING BRAKE
Unit: mm
Standard backlash Repair limit Repair or

3 Face runout of disc
0.4 0.8 replace
Rebuild
(Thickness of disc
Min. 20
4 Thickness of disc 25 must not be under
20 mm)
Max. 20
Thickness of pad (including thick- Replace
5 21.5 11.5
ness of plate)
Standard dimen- Standard clear- Allowable
Tolerance
sion of blade ance clearance
0
22.3
-0.3
Clearance between blade and
6 Standard dimen- Correct or replace
brake assembly Tolerance
sion of brake 1.0 0 0.4 1.5
assembly
+0.4
22.3
-0.1
HM400-1L 10-87
STRUCTURE AND FUNCTION PARKING BRAKE CALIPER
PARKING BRAKE CALIPER
1. Adjuster OUTLINE
2. Piston
3. Piston shaft
● A piston guide is installed to caliper (5). Piston (2)
4. Pad
and piston shaft (3) are inserted, and the rotation of
5. Caliper
piston shaft (3) moves piston (2) in the axial direc-
tion to bring pad (4) into tight contact.
● The lever 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 position.
10-88 HM400-1L
STRUCTURE AND FUNCTION SPRING CYLINDER
SPRING CYLINDER
1. Outer spring OUTLINE

2. Inner spring
3. Piston
● The oil pressure from the parking brake solenoid
4. Cylinder
valve pushes the spring and releases the parking
5. Boot
brake. When the engine is stopped, the parking
6. Rod
brake is applied by springs (1) and (2), so the
machine can not move.
HM400-1L 10-89
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID
PARKING BRAKE SOLENOID
1. Solenoid valve assembly FUNCTION

2. Block
● The parking brake solenoid is installed on the right
A. Outlet port
rearside the front frame. When the parking brake
P. Inlet port
switch is turned ON, the solenoid valve is activated.
T. Drain port
This sends the brake oil to the parking brake spring
cylinder and sets the parking brake to the PARK-
ING position. When the parking brake is turned
OFF, the solenoid valve is unactivated, and the
brake oil pressure is removed from the parking
brake spring cylinder to set the machine to the
TRAVEL condition.
● Parking brake solenoid:
● activated: TRAVEL
● unactivated: PARKING
10-90 HM400-1L
STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
FRONT
1. Front suspension cylinder

2. Arm
3. Lateral rod
4. Dust cover
HM400-1L 10-91
Unit: mm

Clearance between pin and bush- size Shaft Hole clearance limit
5
ing
60 -0.030 +0.046 0.030 – 0.3 Replace
-0.076 0 0.122
Clearance between pin and bush- -0.030 +0.046 0.030 –
6 ing 60 -0.076 0 0.122 0.3
10-92 HM400-1L
REAR
HM400-1L 10-93
1. Arm
2. Equalizer bar
3. Lateral rod (center)
4. Spring
5. Rear suspension
6. Lateral rod (rear)
10-94 HM400-1L
Unit: mm

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

ing -0.076 0 0.122
OUTLINE
● The suspension supports the weight of the machine. It also reduces
any impact caused by unevenness in the road surface and provides a
comfortable ride for the operator. By ensuring that all the tires are
always in contact with the road surface, it maintains the stability of
the machine, and also fulfills the operating performance by ensur-
ing that the machine can accelerate, brake, and turn.
● The suspension cylinders reducing the impact from the road surface
are a hydro-pneumatic type. The inside of the suspension cylinder
is charged (sealed) with oil and nitrogen gas. In this way, the com-
pression 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.
HM400-1L 10-95
2. Center, rear suspension
The center axle and rear axle are both fixed to arms. The center axle
is joined to the equalizer bar through a spring, and the rear axle is
joined through the rear suspension cylinder. The arm and equalizer
bar oscillate in accordance with the condition of the road surface to
keep the wheels in contact with the road surface.
The main frame and arm are connected by a lateral rod and receive
the lateral load.
10-96 HM400-1L
STRUCTURE AND FUNCTION SUSPENSION CYLINDER
SUSPENSION CYLINDER
1. Oil level valve

2. Feed valve
3. Retainer
4. Rod
5. Flange
6. Cylinder
HM400-1L 10-97
STRUCTURE AND FUNCTION SUSPENSION CYLINDER
Unit: mm

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

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
creates a shock-absorbing effect.
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 sur-
face, 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 ball (6), and is
sent to chamber (1) only through orifice (5), so the controlled flow
of oil passing through the orifice less than during retraction. In this
way, the amount of oil returning to chamber (1) is restricted to pro-
vide a shock-absorbing effect.
1. Oil chamber
2. Nitrogen gas chamber
3. Cavity
4. Orifice
5. Orifice
6. Check ball
10-98 HM400-1L
STRUCTURE AND FUNCTION OSCILLATION HITCH
OSCILLATION HITCH
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
HM400-1L 10-99
10-100 HM400-1L
Unit: mm

1 Standard shim thickness size Shaft Hole clearance limit
–
2 Standard shim thickness –
Clearance between bushing and -0.036 +0.054 0.036 –
3 115 -0.090 0 0.144 –
front frame
Clearance between shaft and bush- -0.036 +0.054 0.036 –
4 ing 85 -0.066 0 0.120 –
5 Clearance between shaft and bear- 85 -0.036 0 0.016 – –

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

ing -0.058 0 0.112
Clearance between front frame -0.036 +0.054 0.036 –
7 and shaft 85 -0.058 0 0.112 –
9 Clearance between front frame 85 -0.036 +0.054 0.036 – –

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

and pin -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 and 0 -0.017 -0.080 –

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

bearing -0.083 0 0.146
Clearance between rear frame and 0 -0.013 -0.080 –
16 bearing 420 -0.045 -0.080 0.032 –
Clearance between bearing and -0.056 0 0.020 –

17 hitch frame 300 -0.108 -0.036 0.108 –
OUTLINE
● The front frame and the rear frame are connected by the ● In addition, the output from the transmission is trans-
oscillation hitch. mitted from center drive shaft (3) to coupling (9). It is
then transmitted from coupling (11) through the rear
● Front frame (2) is connected with bearings and pins (6)
drive shaft to the rear axle.
and (12); rear frame (4) is connected with a spacer,
retainer, and bearing. This makes it possible for the
front and rear frames to articulate and oscillate.
HM400-1L 10-101
STRUCTURE AND FUNCTION STEERING, HOIST OIL PRESSURE PIPING DIAGRAM
STEERING, HOIST OIL PRESSURE PIPING DIAGRAM
1. Steering, hoist control pump (SAR(3)100+100+(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
10-102 HM400-1L
STRUCTURE AND FUNCTION DUMP BODY CONTROL
DUMP BODY CONTROL
1. Dump control lever FUNCTION

2. Pilot check valve
3. EPC valve ● This control is carried out by the body position sensors.
4. Hoist cylinder The body position sensor senses the position of the
5. Hoist valve dump body and the retarder controller (brake control-
6. Hydraulic pump (SAR(3)100+100+(1)8) ler: E-SPEC) controls it.
7. Body positioner sensor
● The signal from the dump control lever is controlled by
the retarder controller (brake controller: E-SPEC), 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.
HM400-1L 10-103
STRUCTURE AND FUNCTION HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
1. Hydraulic oil filter

2. Breather
3. Oil level gauge
4. Drain plug
5. Bypass valve
6. Element
7. Strainer
10-104 HM400-1L
STRUCTURE AND FUNCTION FLOW AMP VALVE
FLOW AMP VALVE
1. Valve CL To steering cylinder OUTLINE

2. Valve L To steering valve
3. Orifice P To steering valve
● The flow amp valve consists of the directional valve,
4. Spring PP From steering valve
amplifying stage, priority valve, relief valve, pressure
5. Pin HP From hydraulic pump
control valve, and suction valve.
6. Valve LS From steering valve
● It amplifies the oil flow sent from ports L and R of the
7. Valve HT From hoist valve
steering unit by the specified ratio. The amplified oil then
8. Plug T To steering valve
goes from ports CL and CR of the flow amp valve and
9. Valve EF To hoist valve
flows to the steering cylinder. The amplified oil flow is
10. Spool R From steering valve
proportional to the amount the steering wheel is turned.
11. Valve body CR To steering cylinder
12. Stopper
HM400-1L 10-105
OPERATION
1. At neutral
● Port P of steering unit (7) is closed and the flow amp ● For priority valve (2) also, the oil is drained from relief
valve is closed at chamber M of pressure control valve valve (1). Before starting, priority valve (2) is pushed to
(3). the far left by the spring, so in reality, port EF of the
● Ports L, R, and T of steering unit (7) are connected to flow amp valve is almost closed.
each other, so the oil passes through port T of the flow ● At the same time the engine starts, oil flows to port HP
amp valve and is drained to the hydraulic tank. By con- of the flow amp valve and then flows to port P of steer-
necting in this way, directional valve (6) is always held ing unit (7). At the same time, the pilot pressure that is
at the neutral position by the springs on both sides. For connected to port PP suddenly rises. As a result of bal-
this reason, at the neutral position, the reaction or ancing with the spring and moving to the right, port EF
impact from the steering cylinder is not transmitted to opens and the oil flows to the hoist piping.
steering unit (7).
10-106 HM400-1L
2. When turning
● When steering unit (7) is actuated, the oil sent from
port P of priority valve (2) passes through ports P and L
of steering unit (7) and enters port L of directional
● The oil at the steering cylinder head end goes out from
valve (6). At the same time, oil from priority valve (2)
suction valve (5). It then goes from port CR of direc-
also enters chamber M of pressure control valve (3).
tional valve (6) through check valve (4) and is drained
● When the oil entering directional valve (6) rises to a to the hydraulic tank from port HT of the flow amp
pressure greater than the force of the spring, it pushes valve.
the spool to the right, and enters chamber C of pressure
● If there are rocks on the road or the road surface is
control valve (3). When it rises to a pressure greater
uneven, and any abnormal external force is applied to
than the force of the spring in chamber C, it pushes the
the tires and steering cylinder, relief valves (8) and (9)
spool to the left.
of suction valve (5) open at a pressure of 23.5 Mpa
● The oil that is already in chamber M of pressure control {240 kg/cm2}, so the oil passes through directional
valve (3) enters chamber N when the spool is pushed to valve (6) and is drained to the hydraulic tank.
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.
HM400-1L 10-107
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
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. Lever cover
10-108 HM400-1L
OUTLINE
● The steering valve is connected directly to the shaft of the steering
wheel. It switches the flow of oil from the steering pump to the left
and right steering cylinders to determine the direction of travel of
the machine.
● The orbit-roll valve, broadly speaking, consists of the following
components: rotary type spool (9) and sleeve (8), which have the
function of selecting the direction, and the Gerotor set (a combina-
tion of rotor (5) and stator (10)), which acts as hydraulic motor dur-
ing normal steering operations, and as a hand pump (in fact, the
operating force of the steering wheel is too high, so it cannot be
operated) when the steering pump or engine have failed and the
supply of oil is stopped.
STRUCTURE
● Spool (9) is connected to the drive shaft of the steering wheel, and
is connected to sleeve (8) by center pin (7) (this is not touching the
spool when the steering wheel is at the neutral position) and center-
ing spring (2).
● Drive shaft (3) is meshed at the top with center pin (7) and forms
one unit with sleeve (8). The bottom is meshed with the spline of
rotor (5) of the Gerotor set.
● Valve body (4) has five ports. These are connected to the pump cir-
cuit, tank circuit, steering cylinder head end, bottom end, and flow
amp valve pilot end. In addition, the port at the pump end and the
port at the tank end are connected by the check valve inside the
body. If there is any failure in the pump or engine, this check valve
acts to suck in oil directly from the tank.
HM400-1L 10-109
CONNECTION BETWEEN HAND PUMP

AND SLEEVE
● The diagrams to the right show the connections with the sleeve
ports used to connect the suction and discharged ports of the Gero-
tor.
● If the steering wheel has been turned to the right, ports a, c, e, g, i,
and k are connected 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 condi-
tion in Fig. 1, ports 1, 2, and 3 are the discharge ports of the Gerotor
set. 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 flows in from
the pump. In the steering wheel is turned 90°, the condition changes
to the condition shown in Fig. 2. In this case, ports 1, 2, and 3 are
the suction ports, and are connected to ports i, k, and c. Ports 5, 6,
and 7 are discharge ports, and are connected to ports d, f, and h.
10-110 HM400-1L
● In this way, the ports of the Gerotor acting as delivery ports are con-
nected to ports which are connected to the end of the steering valve
spool. The ports acting as suction ports are connected to the pump
circuit.
● Adjusting delivery in accordance with angle of steering wheel: for
every 1/7 turn of the steering wheel, the inner teeth of the Gerotor
gear advance one position so the oil flow from the pump is adjusted
by this movement. The oil delivered from the pump is directly pro-
portional to the amount the steering wheel is turned.
HM400-1L 10-111
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 dif-
ference 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 cylinder. When the turning of the steering wheel is
stopped, the Gerotor also stops turning, so no more oil is sent to the cyl-
inder and the oil pressure 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 variation a) of the sleeve and
spool, so the steering wheel returns to the NEUTRAL position.
10-112 HM400-1L
STRUCTURE AND FUNCTION STEERING CYLINDER
STEERING CYLINDER
Unit: mm

Clearance between piston rod and size Shaft Hole clearance limit
1
bushing
-0.030 +0.271 0.105 –
70 0.475
-0.104 +0.075 0.375
Clearance between piston rod sup- 0 +0.174 0.100 –
2 65 1.0
port shaft and bushing -0.074 +0.100 0.248
Replace
Clearance between cylinder bot-
0 +0.174 0.100 –
3 tom support shaft and 65 1.0
-0.074 +0.100 0.248
bushing
4 Cylinder bore +0.15
120 –
0
HM400-1L 10-113
STRUCTURE AND FUNCTION HOIST VALVE
HOIST VALVE
10-114 HM400-1L
AB: To hoist cylinder bottom
AH: To hoist cylinder head
P: From demand valve
PA: From EPC valve (pressurizing for LOWER, FLOAT)
PB: From EPC valve (pressurizing for RAISE)
T: To hydraulic tank
T2: To pilot check valve
1. Valve body
2. Hoist spool
3. Check valve
4. Housing
5. Relief valve
Unit: mm

Free length Installed Installed Free Installed
A Spool return spring
x O.D. length load length load
63.4 x 61 61 308 N – 277 N
Replace spring
B Spool return spring 47 x 36 47 0N – – if damaged or
C Spool return spring 47.5 x 41 45.2 308 N – 277 N deformed
D Spool return spring 87.6 x 52 60 1372 N – 1235 N

E Spool return spring 97.8 x 35 86 822 N – 740 N
F Check valve return spring 84.7 x 26.6 47.5 13 N – 11 N
HM400-1L 10-115
OPERATION
HOIST VALVE AT HOLD POSITION
● The oil from the demand valve enters port C. The pas- ● The ports to the hoist cylinder are blocked at both the
sage to the hoist cylinder is blocked by hoist spool (2), bottom end and head end, so the hoist cylinder is held
so the oil is drained from tank D to the tank. in position.
10-116 HM400-1L
HOIST VALVE AT RAISE POSITION
● When the hoist lever inside the cab is operated to the ● From chamber A, the oil enters the bottom end of the
RAISE position, hoist spool (2) is moved to the left by hoist cylinder, extends the hoist cylinder, and raises the
the solenoid valve. dump body.
● As a result, the oil flows from chamber C, opens check ● At the same time, the return oil from the head end flows
valve (3), and enters chamber A. from port B to port D, and flows to the tank circuit.
HM400-1L 10-117
HOIST VALVE AT FLOAT POSITION
● When the hoist lever inside the cab is operated to the

FLOAT position, hoist spool (2) is moved to the right
by the solenoid valve. As a result, chamber C and
chamber D, and chamber B and chamber H and cham- ● The bottom end and head end of the hoist cylinder are
ber D are connected. connected inside the hoist valve, so the hoist cylinder is
● The oil from the demand valve passes from chamber C placed in the free condition.
through chamber B and flows to the hoist cylinder. Oil
also flows from chamber C to chamber D, and then
flows to the brake oil cooler circuit.
10-118 HM400-1L
HOIST VALVE AT LOWER POSITION
● When the hoist lever inside the cab is operated from the
● At the same time, the return oil from the head end of
FLOAT position to the LOWER position, hoist spool
the hoist cylinder flows from chamber A to chamber H.
(2) is moved further to the right from the FLOAT posi-
tion by the solenoid valve. As a result, the oil flows ● When the dump body is lowered, the output pressure of
from chamber C, pushes open check valve (3), and the solenoid valve rises and becomes greater than the
enters chamber B. cracking pressure of the pilot check valve. As a result,
the return oil from chamber H returns to the tank
● The oil from chamber B enters the head end of the hoist
through two lines: one from chamber D to the tank, and
cylinder, retracts the cylinder, and lowers the dump
the other from chamber E to the tank.
body.
HM400-1L 10-119
STRUCTURE AND FUNCTION EPC VALVE
EPC VALVE
1. Manual operation button FUNCTION

2. Solenoid assembly
3. Relief valve
● With the EPC valve, the oil from the hydraulic pump is
4. Solenoid assembly (EPC)
controlled by the retarder controller (brake controller:
E-SPEC). It is then sent to the spool of the hoist valve,
A. To hoist valve
and switches the pilot pressure to control the hoist
B. To hoist valve
valve.
P1. From hydraulic pump
T1. To hydraulic tank
T2. To hydraulic tank
10-120 HM400-1L
STRUCTURE AND FUNCTION PILOT CHECK VALVE
PILOT CHECK VALVE
1. Body A. From hoist valve

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

Replace spring
Free length Installed Installed Free Installed
6 Spring if damaged or
x O.D. length load length load
deformed
198.5 x 53 70 821.2 N – 739 N
HM400-1L 10-121
STRUCTURE AND FUNCTION HOIST CYLINDER
HOIST CYLINDER
Unit: mm

Clearance between cylinder and size Shaft Hole clearance limit
1 bushing
-0.043 +0.277 0.104 –
140 -0.143 +0.061 0.420 0.720
2 Clearance between piston rod and 90 -0.036 +0.270 0.097 – 0.693 Replace
bushing -0.123 +0.061 0.393
Clearance between piston rod sup- +0.004
3 port pin and bearing 60 – -0.019 – 1.0
Clearance between cylinder sup- +0.004

4 port pin and bushing 60 – -0.019 – 1.0
10-122 HM400-1L
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
STEERING, HOIST + PILOT PUMP

SAR (3)100+100+(1)8
Unit: mm
Model Standard clearance Clearance limit
SAR(3)-100
1 Side clearance 0.13 – 0.18 0.21
SAR(3)-100
SAR(1)-8 0.10 – 0.15 0.19
Clearance between inside diameter SAR(3)-100
0.060 – 0.149 0.20
2 of plain bearing and outside of SAR(3)-100
Replace
diameter of gear shaft SAR(1)-8 0.06 – 0.144 0.20
Model Standard size Tolerance Repair limit
SAR(3)-100 0
14
3 Depth for knocking in pin SAR(3)-100 -0.5
–
0
SAR(1)-8 10
-0.5
4 Rotating torque of spline shaft 8.7 – 20.7 Nm
Standard
Rotating Delivery Delivery
delivery
Model speed pressure amount limit
Discharge amount amount
(rpm) (MPa) (L/min) –
(L/min)
– Oil: EO10-CD
Oil temperature: 45–55°C SAR(3)-100
231.5 213.5
SAR(3)-100 2,500 20.6
SAR(1)-8 17.2 15.8
HM400-1L 10-123
TRANSMISSION + DIFFERENTIAL LOCK PUMP

SAR (3)100+(1)12+8
Unit: mm
SAR100 0.13 – 0.18 0.21
1 Side clearance
SAR12
0.10 – 0.15 0.19
SAR8
Clearance between inside diameter SAR100 0.06 – 0.149
Replace
2 of plain bearing and outside of SAR12 0.20
0.06 – 0.144
diameter of gear shaft SAR8
3
Depth for knocking in pin 14 0
–
4 10 -0.5
Standard
delivery
Discharge amount amount
(rpm) (MPa) (L/min) –
– Oil: EO10-CD (L/min)
Oil temperature: 45–55°C SAR100 231.5 213.5
SAR12 2,500 20.6 26.8 24.6
SAR8 17.2 15.8
10-124 HM400-1L
BRAKE COOLING + BRAKE PUMP

SAR (3)80+(1)25
Unit: mm

1 Side clearance SAR80
0.10 – 0.15 0.19
SAR25
Clearance between inside diameter SAR80 0.06 – 0.149
2 of plain bearing and outside of 0.20 Replace
diameter of gear shaft SAR25 0.06 – 0.144

3
Depth for knocking in pin 14 0
–
4 10 -0.5

Standard
delivery
Discharge amount amount –
(rpm) (MPa) (L/min)
– Oil: EO10-CD (L/min)
Oil temperature: 45–55°C
SAR80 2.9 200 –
2,500
SAR25 20.6 57.0 50.7
HM400-1L 10-125
AUXILIARY STEERING PUMP

SBL(1)21
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.10 – 0.15 0.19
Clearance between inside diameter
2 of plain bearing and outside of 0.060 – 0.119 0.20
Replace
diameter of gear shaft
3 Depth for knocking in pin 0
10 –
-0.5
Standard
Delivery Delivery
Discharge amount Rotating speed delivery
pressure amount limit –
– Oil: EO10-CD (rpm) amount
(MPa) (L/min)
Oil temperature: 45–55°C (L/min)
3,500 20.6 67.6 62.4
10-126 HM400-1L
DIFFERENTIAL LOCK PUMP

SBR(1)8+8
Unit: mm
Standard clearance Clearance limit

1 Side clearance
0.10 – 0.15 0.19
Replace
Clearance between inside diameter
2 of plain bearing and outside of 0.060 – 0.119 0.20
diameter of gear shaft
Standard
Delivery Delivery
Discharge amount Rotating speed delivery
pressure amount limit
3 Oil: EO10-CD (rpm) amount –
(MPa) (L/min)
Oil temperature: 45–55°C (L/min)
3,500 20.6 25.2 23.7
HM400-1L 10-127
STRUCTURE AND FUNCTION CAB TILT
CAB TILT
1. Tilt stopper bar

2. Tilt cylinder
3. Breather
4. Adapter
5. Pin
10-128 HM400-1L
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
1. Air conditioner unit FUNCTION

2. Filter
3. Control panel The air conditioner makes a pleasant operating environment
4. Compressor for the operator and acts to reduce fatigue.
5. Receiver dryer
6. Condenser
HM400-1L 10-129
AIR CONDITIONER UNIT
1. FRESH/RECIRC selector damper

2. Evaporator
3. Heater core
4. Blower motor
A. Hot water inlet port

B. Hot water outlet port
C. Refrigerant gas inlet port
D. Refrigerant gas outlet port
E. Dehumidified coolant drain port
10-130 HM400-1L
RECEIVER DRYER
1. Body
2. Sight glass
3. Dryer
4. Dryer
HM400-1L 10-131
CONDENSER
1. Fin
2. Tube
A. Refrigerant gas inlet port

B. Refrigerant gas outlet port
10-132 HM400-1L
COMPRESSOR
1. Case
2. Clutch
A. Suction service valve

B. Discharge service valve
HM400-1L 10-133
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
NETWORK DATA
1. From machine monitor to each controller
● Switch input data
● Option setting data
2. From each controller to machine monitor
● Display data related to each controller
● Service mode data
● Troubleshooting data
3. From transmission controller to machine monitor
● Model selection data
10-134 HM400-1L
OUTLINE
1. With the machine monitor system, the controllers on the network use the data from the sensors installed to all parts of the
machine to observe and control the condition of the machine and transmit that data as network data to the machine moni-
tor. The machine monitor is a system to display this data and inform the operator of the condition of the machine.
2. There are two types of display on the machine monitor: the normal mode and the service mode.
3. The items that are always displayed for the operator are the normal mode items. Their main content is as follows.
A. Normal display items

● Meters (speedometer, tachometer)
● Gauges (engine coolant temperature, torque converter oil temperature, retarder oil temperature, fuel level)
● Pilot display
● Service meter, odometer (character display)
B. Items displayed when there is abnormality

Caution, action code display (If an action code is being displayed, press machine monitor mode selector switch (2),
then release it. A failure code (6-digit) is then displayed.)
C. When the filter, oil replacement interval is reached, the item needing replacement is displayed in the character dis-
play.
D. Other functions using the character display and the machine monitor mode selector switch to operate include the fol-
lowing: Total reverse distance traveled display, filter, oil replacement interval reset, telephone number input, and lan-
guage selection.
4. To make it easier to troubleshoot controllers (including the monitor panel itself), a service mode function is provided. Its
main content is as follows.
A. Displaying trouble data for electrical components, deleting from memory

● Displays electrical components failure data from each controller that is saved in machine monitor
● Deletes data from memory
B. Trouble data for machine

● Displays machine failure data from each controller that is saved in machine monitor
C. Real-time monitor
● Takes input and output signal values recognized by each controller on network and displays in real time
D. Reduced cylinder mode

This function is used to stop the supply of fuel sprayed from the fuel injector. This makes it possible to determine the
cylinder with defective combustion.
E. ECMV compensation
This is used for the initial adjustment of the transmission.
F. Changing replacement time for filter, oil

This changes the original setting for the replacement interval.
G. Controller initialize
This function is used to set the machine monitor when the machine is shipped from the factory.
HM400-1L 10-135
5. The service mode has the following functions.
A. Setting service meter

● This can set service meter values recorded in machine monitor memory
● However, values can only be increased from present value (they cannot be decreased).
B. Setting total travel distance

● This can set travel distance values recorded in machine monitor memory
C. Setting distance traveled in reverse

● This can set values for distance traveled in reverse recorded in machine monitor memory.
6. The machine monitor system consists of the monitor panel, buzzer, and switches, network, controllers on the network, and
the sensors inputting data to the monitor panel.
10-136 HM400-1L
MACHINE MONITOR
1. Speedometer 23. Machine monitor, option system caution lamp

2. Engine tachometer 24. Engine system caution lamp
3. Brake cooling oil temperature gauge 25. Transmission system caution lamp
4. Torque converter oil temperature gauge 26. Retarder system caution lamp
5. Engine coolant temperature gauge (Brake system caution lamp: E-SPEC)
6. Fuel gauge 27. Tilt caution lamp
7. Character display 28. Seat belt caution lamp
8. Turn signal pilot lamp (R, H) 29. Parking brake pilot lamp
9. Turn signal pilot lamp (L, H) 30. Retarder pilot lamp
10. Front lamp high beam pilot lamp (Overrun protection brake pilot lamp: E-SPEC)
11. Gearshift lever position pilot lamp 31. Exhaust brake pilot lamp (option)
12. Shift indicator 32. Inter-axle differential lock pilot lamp
13. Lock-up pilot lamp 33. Left and right differential lock pilot lamp
14. Shift hold pilot lamp (Machine with locking differential)
15. Power mode pilot lamp (high power mode) 34. Dump body pilot lamp
16. Power mode pilot lamp (economy mode) 35. Auxiliary steering pilot lamp
17. Central warning lamp 36. Preheating pilot lamp
18. Maintenance caution lamp 37. Brake cooling oil temperature caution lamp
19. Battery charge circuit caution lamp 38. Torque converter oil temperature caution lamp
20. Steering oil temperature caution lamp 39. Engine coolant temperature caution lamp
21. Engine oil pressure caution lamp 40. Fuel level caution lamp
22. Retarder oil pressure caution lamp
(Brake oil pressure caution lamp: E-SPEC)
HM400-1L 10-137
41. Travel speed compensation switch [SW1]

42. Rotary switch [SW2]
43. Rotary switch [SW3]
44. Switch for setting left and right differential lock [SW5-4]
45. Dipswitch [SW5-3]
46. Switch for setting exhaust brake [SW5-2]
51. Dipswitch (SW6-1]
10-138 HM400-1L
OPTION SETTING CONNECTOR DIAGRAM
52. Option setting connector [OP1]

58. Setting connector [OP7]
ADJUSTING MACHINE MONITOR

1. For details on setting the rotary switches, the switches, and options setting connectors at the rear face of the machine mon-
itor, see TESTING AND ADJUSTING, Adjusting machine monitor.
2. Precautions
A. When setting, follow the instructions in TESTING AND ADJUSTING, Adjusting machine monitor, and do not
change them.
B. When moving the switches, use a precision screwdriver and turn slowly.
C. Be careful not to touch anything except the switches inside the grommet.
D. Be careful not to let any dirt or dust get in.
E. After completing the setting, return the grommet securely to its original position.
HM400-1L 10-139
MACHINE MONITOR NORMAL DISPLAY FUNCTIONS

: Lights up U: Sounds intermittently
✩1: means that lamps light up while machine monitor check switch is ON
✩2: shows that all lamps light up for approximately two seconds after starting → all off for one
second
Related actuation ✩1 When ✩2

machine Immediately
Display Display Display range/ Method of Central monitor after
No. Device Color Alarm Remarks
item category conditions display warning check starting
buzzer switch is switch is
lamp
operated turned ON
Note: When machine monitor
Scale: 0 - 80 km/h or 0 - 50
check switch is operated, display
White mph Analog
Meter Movement Background ⎯ ⎯ ⎯ starts from present position,
(mph display is only display (Note) completes one cycle, and
Travel color: Black when non-SI is used)
1 returns to the starting position
speed
Lights up
When side lamps light
Backlight LED Amber up when ⎯ ⎯
actuated
Scale:
0 - 3400 rpm (red check switch is operated, display
White, red zone: Analog
Meter Movement Background More than 2500 ⎯ starts from present position,
display (Note)
Engine rpm) completes one cycle, and
2 color: Black
speed returns to the starting position
Lights up
Backlight LED Amber when ⎯ ⎯
up
actuated
Scale:
50 - 150°C check switch is operated, display
White, red (red zone: Analog
Gauge Movement Background More than ⎯ ⎯ ⎯ starts from present position,
display (Note)
120°) completes one cycle, and
color: Black
returns to the starting position
3 Retarder oil
Lights up
37 temperature Caution LED Red
When temperature is
when
more than 120°
abnormal
Lights up
actuated
Scale:
White, red (red zone: More than Analog
Gauge Movement Background ⎯ ⎯ ⎯ starts from present position,
display (Note)
color: Black
Torque returns to the starting position
4 converter Lights up
38 oil Caution LED Red
When temperature is
when
temperature more than 120°
abnormal
Lights up
up
actuated
Scale:
White, red (red zone: Analog
Gauge Movement Background More than ⎯ ⎯ ⎯ starts from present position,
display (Note)
color: Black returns to the starting position
5 Engine
coolant Lights up
39 temperature When temperature is
Caution LED Red when
more than 102°
abnormal
Lights up
up
actuated
Scale: check switch is operated, display
White, red Analog
Gauge Movement Background EMPTY-FULL ⎯ ⎯ ⎯ starts from present position,
display (Note)
completes one cycle, and
color: Black returns to the starting position
6 Fuel level When below specified
Lights up
40 gauge Caution LED Red
level (amount of fuel
when ⎯ ⎯
remaining in tank is
less than 75 L) abnormal
Lights up
actuated
Actuated
Service 0 - 65535.0h
when
meter engine is
Service Display * Displayed on top
⎯ ⎯
When time exceeds 65535.0h,
(normal running
meter letters: line of character stops at 65535.0h
display display
Ratio of
items) Black movement
7 LCD
Background to time 1:1
color:
Odometer Green 0 - 999999.9km
Actuated When distance exceeds
(normal Odometer
* Displayed on bottom
when ⎯ ⎯ 999999.9km, stops at
display line of character
traveling 999999.9km
items) display
10-140 HM400-1L
Related actuation When Immediately

machine after
Display Display range/ Central monitor
No Display item Device Color Method of display Alarm starting Remarks
category conditions warning check switch is
buzzer switch is
lamp turned ON
operated
When abnormality
When abnormality or or Note 1: Top line displays
failure occurs on
failure occurs on "HM400-1"
machine, top line
machine Note 2: Top line displays
Action code Action code shows action ⎯ ⎯ Note 1 Note 2
* Displayed on top and code; "KOMATSU", bottom
bottom line
bottom lines of displays "SYSTEM
displays remedy or
character display CHECK"
nature of failure
Top line displays
failure code (6
When there is digit) and
abnormality or failure, controller that
See separate information
Failure press mode switch ">". detected problem;
Failure code ⎯ ⎯ for details of failure
code * Displayed on top bottom line
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 separate information
Other displays replacement mode selector switch selector switch ">" for details of failure
time reset, "< >" or "<" to switch display
telephone screen
No. setting,
language
selection
Brightness
When side lamps light reduced one level
Night lighting Backlight LED Green ⎯ ⎯
up when side lamps
light up
When operated:
Lights up
Right turn
8 LED Green When operated When not ⎯ ⎯
signal
operated: Goes
out
When operated:
Lights up
9 Left turn signal LED Green When operated When not ⎯ ⎯
operated: Goes
out
When operated:
Lights up
10 High beam LED Blue When operated When not ⎯ ⎯
operated: Goes
out
11 Gearshift lever When gearshift lever is * Flashes when neutral
LED Green Lights up (*) ⎯ ⎯
(R2) position R2 at R2 safety is actuated
(R1) position R1 at R1 safety is actuated
11 Gearshift lever
Orange When gearshift
lever is
LED Lights up ⎯ ⎯
(N) position N at N
(D) position D Pilot at D safety is actuated
(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
range signal received When shift range
Back- from transmission
ground signal is received
⎯ ⎯
Shift indicator LED controller
12 color: from transmission All light up All light up
* When alarm is
Gray actuated when making
controller
emergency escape, "E"
and "N" are displayed in
turn
Night lighting LED Amber
HM400-1L 10-141

machine after
Display Display Display range/ Method of Central monitor
No Device Color Alarm starting Remarks
item category conditions display warning check switch is
buzzer switch is
lamp turned ON
operated
When
When torque
operated:
converter lock-up is
Lights up
13 Lock-up LED Green actuated and ⎯ ⎯
When not
transmission is set to
operated:
direct drive
Goes out
When
operated:
When shift hold Lights up
14 Shift hold LED Green ⎯ ⎯
switch is operated When not
operated:
Goes out
Pilot
High power
Output mode:
mode Lights up
15 (high LED Green High power mode ⎯ ⎯
power When not
mode) actuated:
Goes out
Economy
Output mode:
mode Lights up
16 LED Green Economy mode ⎯ ⎯
(economy When not
mode) actuated:
Goes out
Central Lights up
When there is
17 warning LED Red when U
lamp abnormality in system abnormal
Note 1: Lamp lights up and at

When warning is
same time action code E01 and
issued for
location for warning is displayed
Maintenance maintenance system, Lights up or
⎯ ⎯
18 LED Red on character display
caution or when filter, oil flashes
Note 2: See Operation and
replacement interval
Maintenance Manual for details
has passed
of applicable item
Battery
When there is Lights up
charge
19 LED Red abnormality in charge when U
circuit
circuit abnormal
caution
Steering oil Lights up
When steering oil
20 temperature LED Red when U
caution temperature rises
abnormal
Engine oil Lights up
When engine oil
21 pressure LED Red when U
caution pressure drops abnormal
Brake
Lights up
cooling oil When brake cooling Note: Actuated only when
22 LED Red when (Note) U(Note)
pressure oil pressure drops alternator R terminal = ON
abnormal
caution
Machine When there is
monitor or abnormality in Lights up
23 option LED Red machine monitor or when U U 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 U U
caution control system abnormal
Transmission When there is

Lights up
abnormality in
25 system LED Red when U U
caution transmission control
abnormal
system
When there is
Retarder abnormality in
system
retarder control
caution Lights up
26 (Brake LED Red system when U U
(When there is
system abnormal
abnormality in brake
caution:
control system:
E-SPEC)
E-SPEC)
When dump body is Lights up
raised and there is
27 Tilt caution LED Red when U
excessive tilt to left or
right abnormal
When
actuated:
Seat belt When seat belt is not Lights up
28 LED Red ⎯ ⎯
caution fastened When not
actuated:
Goes outs
10-142 HM400-1L

machine after
Display Display Display range/ Method of Central monitor
No Device Color Alarm starting Remarks
item category conditions display warning check switch is
buzzer switch is
lamp turned ON
operated
Parking When parking brake
Lights up Note: Actuated when parking
29 brake pilot Red when (Note) U(Note) 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 Lights up
30 protection Orange (When overrun when ⎯ ⎯
brake pilot protection brake is applied
lamp: applied: E-SPEC)
E-SPEC)
Exhaust
brake Lights up
When exhaust brake
31 actuation LED Orange when ⎯ ⎯
is actuated
lamp actuated
(option)
When
Inter-axle operated:
Lights up when inter-
differential Lights up
32 LED Orange axle differential lock is ⎯ ⎯
lock pilot When not
operated
lamp operated:
Goes out
Left and
right
When
differential
Pilot actuated:
lock lamp Lights up when left Lights up
33 (Machine LED Orange and right differential
When not
with lock is actuated
actuated:
differential
Goes out
lock
differential)
When
For details, see operated:
Body pilot Operation and Lights up
(Note) U(Note)
Note: Actuated when gearshift
34 LED Red
lamp Maintenance Manual When not lever is at position other than N
operated:
Goes out
When
operated:
Auxiliary Lights up when Lights up
35 steering LED Red auxiliary steering is ⎯ ⎯
When not
ready lamp actuated
operated:
Goes out
When
operated:
Lights up when
Lights up
36 Preheating
electric heater for
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 central warning lamp, caution lamps,
and pilot lamps light up for approximately two seconds and then go out for one second to carry out a system check.
● The alarm buzzer sounds for two seconds and then stops for one second.
● The shift indicator displays 88 for two seconds and then goes out for one second.
● The indicator gauges and meters carry out the above system check for three seconds and then start normal actuation.
● KOMATSU SYSTEM CHECK is displayed for three seconds on the character display.
2. If the starting switch is turned to the START position before three 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 three seconds have passed after the starting switch was
turned to the ON position.
3. However, even if everything goes to the normal operating condition, the indicator gauges and meters will not work until
three seconds have passed after the starting switch was turned to the ON position. Check central warning lamp, alarm
buzzer, caution lamps, pilot lamps, indicator gauges and meters. Before starting the engine, turn the starting switch to the
ON position, then press the machine monitor check switch. In addition to the instruments and gauges in the system check
when the starting switch is turned ON, the indicator gauges and meters will be actuated. When this is done, the character
display gives the model and software version of the machine monitor.
HM400-1L 10-143
CHECK FUNCTION OF CENTRAL WARNING LAMP, ALARM BUZZER, MONITOR LAMPS

AND METERS
To check the normal display functions of the machine monitor, press the machine monitor check switch to check the actuation.
For details of the actuation, see "When operating machine monitor normal display functions with machine monitor check
switch".
SERVICE METER DISPLAY

The service meter shows the total number of hours of operation of the machine on the top line of the character display.
If the engine is running, the service meter will advance even if the machine is not moving.
The service meter will advance by 0.1 for every 0.1 hour that the engine is running, regardless of the engine speed.
ODOMETER
The odometer shows the total distance that the machine has traveled in units of km on the bottom part of the character display.
If dipswitch 1 (position: 1) at the rear of the machine monitor is set to ON, the display is given in units of miles. Even if the
starting switch is OFF, the service meter and odometer can be displayed while the top ( ) of machine monitor mode selector
switch 1 is kept pressed.
Note:If the starting switch is OFF, and the service meter and odometer are displayed even though the top ( ) of machine mon-
itor mode selector switch 1 is not being pressed, there is probably a failure on the machine, so carry out inspection and mainte-
nance.
Example of service meter and odometer display.
OUTLINE OF SERVICE MODE

OUTLINE
1. Trouble data for electrical system

The system is used to check the trouble data for the electrical sys-
tem of each controller saved in the machine monitor. For details of
the failure codes displayed for the trouble data of the electrical sys-
tem, see the troubleshooting section. After repairing the failure,
check that the system works properly, then delete the trouble data.
The trouble data display for the electrical system is displayed on the
character display as shown at the right.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ : Displays number of times that applicable failure code has
occurred
10-144 HM400-1L
%%%%%: Displays time that has elapsed since failure first
occurred (Present service meter reading - Service
meter reading when problem first occurred = Time
elapsed)
@@@@@: Displays time that has elapsed since failure last
occurred (Present service meter reading - Service
meter reading when problem last occurred = Time
elapsed)
The failure code flashes for failures that are still occurring at
present. The number of times that the failure code for the machine
system has occurred is saved in memory.
2. Trouble data for machine system

The system is used to check the trouble data for the machine system
of each controller saved in the machine monitor. For details of the
failure codes displayed for the trouble data of the machine system,
see the troubleshooting section. After repairing the failure, check
that the system works properly, then delete the trouble data.
The trouble data display for the machine system is displayed on the
character display as shown to the right.
*** : Displays order of trouble data items

###### : Displays failure code
$$$ :Displays number of times that applicable failure code has
occurred
%%%%%:Displays time that has elapsed since failure first
occurred
@@@@@:Displays time that has elapsed since failure last
occurred
The failure code flashes for failures that are still occurring at
present. The number of times that the failure code for the machine
system has occurred is saved in memory.
HM400-1L 10-145
3. Real-time monitor
This function is used when checking the input and output signals
recognized by the controllers on the network. The real-time monitor
display on the character display is as shown at the right.
*** : Displays name of item

#####: Displays ID No. given to each item
%%%: Displays data. If units are used, the unit is displayed on the
right side of the data. By specifying the ID No. given to
each item, it is possible to display the desired two items at
the same time.
*** : Displays specified ID No

%%%: Displays data. If units are used, the unit is displayed on the
right side of the data
10-146 HM400-1L
4. Reduced cylinder mode
For details of this function, see TESTING AND ADJUSTING, Engine reduced cylinder mode operation.
5. ECMV compensation
For details of this function, see TESTING AND ADJUSTING, Adjusting transmission, 2. ECMV compensation.
6. Changing filter, oil replacement time

For details of this function, see the Operation and Maintenance Manual, OPERATION, Character display portion, Filter,
oil replacement time display. This is used when changing the replacement interval.
7. Controller initialize
This function is used only at the factory, so do not touch it.
8. Setting service meter

This is used when replacing the machine monitor with a new part, and setting the appropriate service meter reading for the
machine. For details of the method of operation, see TESTING AND ADJUSTING, Adjusting machine monitor.
9. Setting travel distance total

This is used when replacing the machine monitor with a new part, and setting the appropriate travel distance total value
for the machine. For details of the method of operation, see TESTING AND ADJUSTING, Adjusting machine monitor.
10. Setting reverse travel distance total

This is used when replacing the machine monitor with a new part, and setting the appropriate reverse travel distance total
value for the machine. For details of the method of operation, see TESTING AND ADJUSTING, Adjusting machine mon-
itor.
HM400-1L 10-147
OPERATION METHOD
For details of the operating method of each service mode function, see TROUBLESHOOTING..
For details on setting the service meter, travel distance total, and reverse travel distance total, see TESTING AND ADJUST-
ING. REMARK: When the starting switch is turned OFF, it returns to the normal mode.
10-148 HM400-1L
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROL SYSTEM
AUTOMATIC SHIFT CONTROL SYSTEM

(Transmission control system with all-range electronic modulation)
HM400-1L 10-149
STRUCTURE AND FUNCTION AUTOMATIC SHIFT CONTROL SYSTEM
OUTLINE
● The transmission controller receives the shift position signal for the gearshift lever, the accelerator signal for the accelera-
tor pedal, the speed signal for the transmission, and the other signals from the switches and sensors. It then automatically
controls the transmission and shifts it to the optimum speed range.
● In addition to the shift control, the transmission controller also controls the torque converter lock-up solenoid and operates
the brake to prevent overrun. Each clutch pack of the clutch packs and torque converter lock-up clutch in the transmission
is equipped with an electronically controlled modulation valve, and each clutch pack is independently controlled. In this
way, the initial pressure, build-up ratio, and torque-off time for each clutch is controlled according to the condition of the
machine. This reduces the gearshifting shock and prevents shift hunting, this improves the durability of the clutches.
● The transmission shift controller uses the signals from the switches and sensors to drive the machine monitor displays and
caution and pilot lamps, and transmits this data to the network.
10-150 HM400-1L
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
1. Self-diagnostic display window

2. Connector ● Speed sensors are installed at three places (transmission
3. Case input shaft, intermediate shaft, and output shaft). This
4. Motherboard makes it possible to detect slippage of the transmission
5. Model selector switch (rotary switch 1) clutches and to protect the transmission when there is
6. Model selector switch (rotary switch 2) any abnormality in the hydraulic system.
OUTLINE ● It connects to the network and shares various data with
other controllers.
The transmission controller controls the transmission sys- ● It receives input of the model selection data (what
tem. It has the following features and functions. model it is mounted on), and uses the network to con-
● It has a high power mode and economy mode, and the tact other controllers. (For details of the method of set-
gearshifting pattern can be selected. ting, see INSPECTION, MAINTENANCE, AND
● The braking mode is the mode when the brake is used. TROUBLESHOOTING.)
By raising the gearshifting point and increasing the ● It has a self-diagnostic function which divides the input
speed of the brake cooling pump it is possible to raise and output systems further into small parts.
the cooling effect of the retarder and make effective use ● The self-diagnostic function is displayed in two digits.
of the engine brake.
● When a failure is detected, it transmits the details to the
● It controls the torque converter lock-up solenoid valve, network and displays it on the other displays.
overrun prevention solenoid valve, and exhaust brake
● It uses the machine monitor to display if the failure is
solenoid valve.
still existing.
● It controls the inter-axle differential lock solenoid valve
● It provides an escape function for use when there is a
according to the output command from the retarder
failure in the electrical system.
controller (brake controller: E-SPEC).
● It is separate from the gearshift lever.
● To reduce the shock when shifting gear, it outputs the
throttle correction command to the engine controller
when shifting gear and limits the engine speed.
HM400-1L 10-151
ATC1 ATC2 ATC3A ATC3B

Proportional solenoid power
1 æ 1 1 Connector check 1 Alternator terminal R input
source input 24V
Transmission input shaft speed

2 æ 2 ECMV output 1st (+) 2 2 æ
input
Power source output (24V) for Brake cooling oil temperature

Transmission output shaft speed (front wheel) signal input
3 torque converter oil pressure 3 ECMV output 3rd (+) 3 3
input
sensor
Power source input (24V) for

Engine load condition signal
4 overrun prevention solenoid 4 ECMV output High (+) 4 4 Fuel level signal input
input
output command
Power source input (24V) for

Throttle correction command
5 exhaust brake solenoid output 5 ECMV output Rev (+) 5 5 æ
output
command
Potentiometer power source

6 æ 6 æ 6 6 æ
output (5V)
Battery direct power source Torque converter oil pressure Torque converter oil temperature
7 7 ECMV output Low (+) 7 7
input (24V) signal input signal input
ECMV output inter-axle Inter-axle differential lock Brake cooling oil temperature
8 GND 8 8 8
differential lock (+) command input (center wheel) signal input
Transmission oil temperature

9 Power source input (24V) 9 ECMV output 2nd (+) 9 æ 9
signal input
10 æ 10 ECMV output lock-up (+) 10 Emergency escape switch input 10 Brake cooling oil temperature (rear
wheel) signal input
Steering oil temperature signal

11 æ 11 æ 11 11 Accelerator signal input
input
Proportional solenoid power Transmission intermediate shaft

12 æ 12 12
source input 24V speed input
Overrun prevention solenoid

13 13 ECMV output 1st, 3rd (-) 13 Engine speed input
output command
Exhaust brake solenoid output

14 14 Sensor power source output (12V) 14 GND (for speed input)
command
15 Transmission cut relay 15 ECMV output High, Rev (-) 15 æ
16 GND 16 æ 16 GND (for sensor)
GND input for torque converter

17 Power source input (24V) 17 ECMV output Low (-) 17
oil pressure
ECMV output inter-axle GND input for inter-axle

18 18
differential lock (-) differential lock
Air cleaner filter condition signal

19 ECMV output 2nd (-) 19 input
20 ECMV output lock-up (-) 20 Learning data reset switch input
21 GND
10-152 HM400-1L
ATC4 ATC5A ATC5B

Auxiliary steering actuation
1 æ 1 Connector check 1
signal 2 input
Hydraulic tank level signal input Gearshift lever position R1

2 æ 2 2
(opt) signal input
Radiator coolant level signal Gearshift lever position R2

3 æ 3 3
input signal input
Gearshift lever position N signal

4 æ 4 æ 4
input
Gearshift lever position D signal

5 æ 5 æ 5
input
Transmission oil filter condition Gearshift lever position 1 signal

6 Network signal output 6 6
signal input input
Speed range N action command 1 Gearshift lever position 2 signal

7 æ 7 7
signal input input
8 æ 8 Speed range N action command 2 8 Gearshift lever position 3 signal

signal input input
9 æ 9 Hydraulic filter condition signal 9 Gearshift lever position 4 signal

input input
Gearshift lever position 5 signal

10 Network signal GND 10 Fill switch input Low 10
input
11 æ 11 Fill switch input lock-up 11 Shift hold signal input
12 Network signal output 12 Fill switch input High 12 æ
13 Fill switch input 1st 13 æ
14 Fill switch input 2nd 14 Model selection 1 input
15 Fill switch input 3rd 15 Model selection 2 input
16 Fill switch input Rev 16 Model selection 3 input
Fill switch input inter-axle

17
differential lock
18 Start signal input
Auxiliary steering actuation

19
signal 1 input
20 æ
HM400-1L 10-153
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
Shifting the transmission up and down is done according to the shift map saved in the controller memory.
There are three types of shift map, depending on the condition of the input signals.
The settings for each mode are as shown in the table below.
Mode Set conditions
When either of the following conditions is fulfilled

1. Brake signal ON
Braking mode
(footbrake, retarder brake operated)
2. Accelerator pedal released
When the following three conditions are fulfilled

1. Brake signal OFF
High power mode (footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at high power
When the following three conditions are fulfilled

1. Brake signal OFF
Economy mode (footbrake, retarder brake not operated)
2. Accelerator pedal depressed
3. Power mode selector switch is at economy
Braking mode:
The shift-down point and the shift-up point are both raised, the engine speed is maintained at a higher level, and the amount of
cooling oil for the retarder is ensured to provide greater effect when the engine is used as a brake.
High power mode:

The high power mode uses the power of the machine to the maximum to provide the maximum payload. However, when the
machine is unloaded or has only a light load (high acceleration), an acceleration-sensitive type variable shifting point is used.
This detects the acceleration of the machine and shifts the transmission up sooner to provide better acceleration and to improve
the fuel consumption, noise, and 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 lowered, the engine speed is maintained at a lower level, and the fuel consumption, noise, and trans-
mission shock are improved. In this mode, the engine output is limited to 90% of the maximum engine output.
10-154 HM400-1L
AUTOMATIC GEARSHIFTING GRAPH

The shift-up/shift-down points, the torque converter lock-up ON/OFF points, and the automatic braking (for overrun preven-
tion) ON/OFF points of each mode are as shown in the figure below.
1. High power mode:

● For the shift-up point, the optimum point between 1750 and 2090 min-1 is selected according to the amount the accel-
erator pedal is depressed, the acceleration of the machine, and the speed range.
● For the shift-down point also, the optimum point between 1120 and 1300 min-1 is selected according to the amount
the accelerator pedal is depressed and the speed range.
2. Economy mode:
● For the shift-up point, the optimum point between 1750 and 1900 min-1 is selected according to the amount the accel-
erator pedal is depressed, the acceleration of the machine, and the speed range.
● For the shift-down point also, the optimum point between 1120 and 1200 min-1 is selected according to the amount
the accelerator pedal is depressed and the speed range.
3. Keeping gear speed in braking mode (foot brake)

● If the travel speed lowers below 10 km/h while the foot brake is applied, the gear speed at that time (F3, F4, F5) is
held.
● If the travel speed lowers below 4 km/h or the foot brake is not applied or the lock-up is kept turned on for a long
period, the lock-up is turned off and a gear speed proper for the travel speed is selected. Accordingly, if the machine
travels downhill with the foot brake applied and the engine speed kept low by the lock-up, the brake cooling oil flow
becomes insufficient and the engine overheats easily.
4. Lock-up
● For the lock-up ON point, the optimum point between 1050 and 1400 min-1 is selected according to the torque con-
verter input speed (engine speed) and output speed (transmission input shaft speed).
● The lock-up OFF point when the footbrake or retarder brake are operated is 950 min-1.
HM400-1L 10-155
● When the footbrake or retarder brake are not operated, it is 850 min-1.
● When the machine moves downhill with the accelerator pedal released, the lock-up is not engaged until the accelera-
tor pedal is depressed or the footbrake is applied.
5. The auto brake ON point when traveling in F6 is 2400 min- 1.
GEARSHIFT LEVER POSITIONS AND SHIFTING METHOD
1. Gearshift lever position D
A. When shifting up (in high power mode):
i. When the gearshift lever is set at position D, the transmission is set to F2 torque converter range.
ii. When the accelerator pedal is depressed, the engine speed rises and accelerates. When the transmission input
shaft speed reaches 1050 - 1400 min-1, the lock-up clutch is engaged, so the torque converter is directly engaged
and the transmission is set to direct travel.
iii. As the engine speed rises further and reaches 1750 - 2070 min-1, the transmission shifts up to F3.
iv. While the transmission is shifting up, the engine speed is also lowered (a command is output to the engine con-
troller) in order to reduce the shock when shifting gear.
v. Immediately after shifting up, the engine speed momentarily goes down, but as the machine accelerates, it rises
again and the transmission shifts up in turn to F4 to F6 in the same way as in iii above.
B. When shifting down (in high power mode):
i. When the load increases and the engine speed drops to 1120 - 1250 min-1, the transmission shifts down one
speed. (For example, when traveling in F6, the transmission shifts down to F5.) While the transmission is shift-
ing up, the engine speed is also raised (a command is sent to the engine controller) in order to reduce the shock
when shifting gears.
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 converter drive.
★ In the above explanation, the set speed or actuation may differ according to the travel conditions. 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

These are the gearshift lever positions for traveling in reverse. The transmission shifts to the range (R1 or R2) specified by the
gearshift lever position.
(Manual shift):
The safety functions related to travel in reverse are the directional inhibitor and reverse safety. If the operation is not correct,
gearshifting is restricted.
4. Gearshift lever position N

At the neutral position, none of the transmission clutches are actuated.
10-156 HM400-1L
SHIFT HOLD FUNCTION

● Press the hold switch on the gearshift lever once to hold the transmission in the present speed range.
● Press the hold switch again to cancel the shift hold function.
● If the speed of the transmission input shaft goes below 750 min-1 while the shift hold function is being actuated, the shift
hold function is automatically canceled.
GEARSHIFTING TIME DELAY

● In the automatic shift range, to prevent mistaken operation caused
by excessive variation in the speed when shifting gears, a time
delay is used to prevent the gears from being shifted within the set
time.
● The gearshifting time delay is controlled precisely by each gear-
shifting pattern through the use of the all-range electronic modula-
tion system.
● The approximate values for the gearshifting pattern and gearshift-
ing time delay are shown in the diagram at the right.
SAFETY FUNCTIONS
1. Down-shift inhibitor function

If gearshift lever is operated D → 5 - 1, 5 → 4 - 1, 4 → 3 - 1, 3 → 2 - 1, 2 → 1
For example, when traveling in D (F6), even if the gearshift lever is operated to 4, the transmission does not shift directly
F6 → F4. It shifts down F6 → F5 → F4 in turn according to the engine speed. (The transmission does not jump two speed
ranges if the operator makes a mistake when operating the gearshift lever. This is to prevent the engine from overrunning.)
2. Neutral safety function

This circuit prevents the engine from starting if the gearshift lever is not at the N position, even if the starting switch is
turned to the START position. (This is a safety circuit to prevent the machine from moving unexpectedly when the engine
is started.)
3. Directional inhibit function

● When traveling in reverse at a speed of more than 3.8 km/h, even if the gearshift lever is operated to D or positions 5
to 1, the transmission will not be shifted immediately to travel forward. The engine speed is lowered to reduce the
travel speed, and when the travel speed goes below 3.8 km/h, the transmission is shifted to FORWARD.
● When traveling forward at a speed of more than 1.9 km/h, even if the gearshift lever is operated to positions R1 or R2,
the transmission will not immediately shift to reverse. The speed range is shifted to N and the engine speed is lowered
to reduce the travel speed. When the travel speed goes below 1.9 km/h, the transmission is shifted to REVERSE.
● When traveling in reverse at a speed of more than 7.2 km/h with the gearshift lever at position R2, even if the gear-
shift lever is operated from R2 to R1, the transmission does not shift to R1. When the travel speed goes below 1.9 km/
h, the transmission is shifted to R1.
● When starting the engine, if the machine is already traveling forward or in reverse at a speed of more than 3.8 km/h,
even if the gearshift lever is operated to a position other than N, the machine will not move and the transmission will
be held at N.
● When the travel speed goes below 1.9 km/h, it is permitted to move the machine. (To prevent overload on power
train, to improve durability and reliability)
4. Power train overrun prevention rear brake function

● If the engine speed rises to more than 2400 min-1 (more than 2350 min-1 in F6), the central warning lamp flashes and
the alarm buzzer sounds.
● If the engine speed rises to more than 2450 min-1 (more than 2400 min-1 in F6), the rear brake is automatically actu-
ated (to prevent overrun of engine, torque converter, and transmission, to improve durability and reliability).
HM400-1L 10-157
5. REVERSE safety
The machine will not travel in reverse if the dump control lever is not at FLOAT and the dump body is not completely
lowered (turnover prevention function). However, if the gearshift lever is at the R1 position and the shift hold switch is
pressed, it is possible to travel in reverse while the switch is being pressed, even if the dump body is not fully lowered.
6. Speed range limit function when dump body is raised

● After dumping the load, if the body is not completely lowered, shifting up is limited.
● If the gearshift lever is at D, the machine starts in F2, and if it is at positions 5 to 1, the machine starts in F1.
● The transmission does not shift up until the body is completely lowered.
SELF-DIAGNOSTIC FUNCTION
● The controller performs a self-diagnosis of the system and displays any failures.
● The details of the self-diagnosis are displayed as a 2-digit code with LEDs.
● If a failure is detected by the self-diagnosis function, the failure data is transmitted to the network and displayed as an
action code on the machine monitor. The transmission system caution, warning lamp, or alarm buzzer may also be actu-
ated.
10-158 HM400-1L
STRUCTURE AND FUNCTION AUTO AUXILIARY STEERING SYSTEM
AUTO AUXILIARY STEERING SYSTEM
1. Auxiliary steering motor OUTLINE

2. Auxiliary steering pump
3. Hydraulic tank
If the engine stops or a failure occurs in the hydraulic pump
4. Steering oil pressure sensor
when the machine is traveling, and the oil in the steering cir-
5. Steering valve
cuit goes below the specified oil pressure, the auto auxiliary
6. Battery relay
steering system automatically actuates the auxiliary steering
pump to ensure the steering oil pressure and to make it pos-
sible to operate the steering. It is also possible to operate it
manually.
HM400-1L 10-159
STRUCTURE AND FUNCTION SENSORS, SWITCHES
SENSORS, SWITCHES
ENGINE SPEED SENSOR
1. Magnet
2. Locknut
3. Wiring harness
4. Connector
FUNCTION
The engine speed sensor is installed to the ring gear of the flywheel housing. It uses the rotation of the gear teeth to generate a
pulse voltage and transmits a signal to the transmission controller.
10-160 HM400-1L
STRUCTURE AND FUNCTION ACCELERATOR SENSOR
ACCELERATOR SENSOR
1. Connector
2. Connector
3. Pedal
OUTLINE
ACCELERATOR SIGNAL
This is installed under the operator’s cab. The accelerator pedal and
accelerator sensor are connected by a link. When the accelerator pedal is
depressed, the movement is passed through the link and rotates the shaft
of the potentiometer inside the accelerator sensor. As a result, the resis-
tance changes. A fixed voltage is impressed between the No. 1 – 3 pins
of the potentiometer. A voltage signal corresponding to the angle of the
accelerator pedal is sent from the No. 2 pin to the transmission control-
ler.
IDLE VALIDATION SIGNAL

This is installed under the operator’s cab. When the accelerator pedal is
released, signal 2 (No. 5 pin) is connected to the ground; when the
accelerator pedal is depressed, signal 3 (No. 6 pin) is connected to the
ground. The engine controller then detects the condition.
HM400-1L 10-161
ENGINE COOLANT TEMPERATURE SENSOR
BRAKE COOLING OIL TEMPERATURE SENSOR
1. Thermistor
2. Plug
3. Wiring harness
4. Connector
FUNCTION
The sensors are installed to the brake cooling piping. They take the change in resistance of the thermistor as the change in the
temperature and transmit a signal to the transmission controller. The signal is sent from the transmission controller through the
network to the machine monitor panel to display the temperature level. When the display on the monitor panel reaches the
specified position, the lamp flashes and the buzzer sounds to warn of a problem.
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 portion detects the temperature, and
when the oil temperature goes above the specified level, the warning lamps lights up and a message is displayed on the charac-
ter display of the monitor panel.
10-162 HM400-1L
FUEL LEVEL SENSOR
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
FUNCTION
The fuel sensor is installed to the side face of the fuel tank. The float moves up and down according 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 certain level, a warning lamp flashes.
HM400-1L 10-163
TILT SENSOR
1. Magnetic resistance particle

2. Leaf spring
3. Damper oil
FUNCTION
The tilt sensor is installed to the rear of the chassis. A magnet supported by a leaf spring is installed to a case charged with
damper oil. It uses the position in relation to the magnetic resistance element to detect the tilt angle of the chassis. The magnet
is supported by the leaf spring, so it does not detect the front-to-rear tilt of the chassis.
10-164 HM400-1L
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 abnormality.
HM400-1L 10-165
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 maintenance caution lamp lights up to warn of the abnormality.
10-166 HM400-1L
BODY POSITIONER SENSOR
1. Bearing
2. Rotor
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 receives
sliding resistance through the link installed to the dump body, and the dump body angle is detected.
HM400-1L 10-167
STRUCTURE AND FUNCTION RETARDER CONTROL SYSTEM
RETARDER CONTROL SYSTEM
10-168 HM400-1L
RETARDER CONTROLLER

2. Rotary switch
3. Motherboard
4. Case
5. Connector
OUTLINE
The retarder controller has the following functions.
1. Retarder control
The electromagnetic proportional valve for the front and rear wheels is controlled according to the operating angle of the
retarder control lever and actuates the retarder brake.
2. 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 (ON/OFF com-
mand) from the transmission controller and actuates the retarder brake by a fixed amount.
3. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) accord-
ing to the position of the dump control lever and actuates the dump body.
HM400-1L 10-169
4. Differential lock control
A. Inter-axle differential lock control
i. The differential lock command is sent to the transmission controller according to the condition of the machine
(differential lock switch, travel speed, etc.).
ii. Based on the command from the retarder controller, the transmission controller drives the ECMV and actuates
the inter-axle differential lock.
B. Left and right differential lock control
i. Depending on the setting of the left and right differential lock selector switch, if the differential lock foot switch
is ON and the speed range is low (F1, F2, F3, R1, R2), the left and right differential lock is actuated.
5. Exhaust brake control

Based on the command from the transmission controller, the exhaust brake solenoid is driven and the exhaust brake is
actuated.
6. Transmission of network data
A. Retarder actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differential lock actua-
tion, accumulator oil pressure drop warning, and other data are transmitted to the monitor panel.
B. The exhaust brake command, overrun prevention, retarder command when there is abuse, and other data sent from
the transmission controller are received.
C. The inter-axle differential lock actuation command, reverse inhibit, and other data are transmitted to the transmission
controller.
10-170 HM400-1L
BRC1 BRC2 BRC3A BRC3B

Power source for +24V output Proportional solenoid power
1 1 1 Connector check 1 æ
sensor source +24V
Rear wheel differential lock

2 2 æ 2 æ 2 æ
solenoid
3 Exhaust brake solenoid 3 æ 3 æ 3 æ
4 Brake cut relay (+24V IN) 4 æ 4 æ 4 æ
Accumulator oil pressure

5 æ 5 æ 5 æ 5 (FRONT)
Inter-axle differential lock Sensor power source +5V (hoist

6 Neutral signal 1 6 6 lever potentiometer, body 6 Accumulator oil pressure (REAR)
command
position)
Battery direct power source Accumulator gas pressure

7 7 æ 7 æ 7
input (FRONT)
Front wheel retarder

8 GND 8 electromagnetic proportional 8 æ 8 Accumulator gas pressure (REAR)
reducing valve (+)
Rear wheel retarder

9 Power source +24V 9 electromagnetic proportional 9 æ 9 æ
reducing valve (+)
Front wheel differential lock

10 10 Hoist EPC valve (+) 10 æ 10 æ
solenoid
11 Kick-out solenoid 11 æ 11 æ 11 æ

12 Hoist selector valve 12 12 Transmission front axle speed 12 Hoist lever potentiometer 2
source +24V
13 Brake cut relay 13 æ 13 Transmission output shaft speed 13 Body position sensor
14 æ 14 Sensor power source +12V 14 GND (pulse) 14 Hoist lever potentiometer 1

(pulse)
15 Neutral signal 2 15 æ 15 æ 15 Steering angle potentiometer
Sensor power source +5V Manual retarder lever

16 GND 16 (retarder lever potentiometer) 16 GND (analog) 16 potentiometer
17 Power source +24V 17 æ 17 æ
Front wheel retarder

18 electromagnetic proportional 18 æ
reducing valve (-)
Rear wheel retarder

reducing valve (-)
20 Hoist EPC valve (-) 20 æ
21 GND
HM400-1L 10-171
BRC4 BRC5A BRC5B

1 RS422 TX(+) 1 Connector check 2 1 æ
2 RS422 RX(+) 2 Exhaust brake switch 2 Brake wear switch FL
3 RS232 TXD 3 Service brake switch 3 Brake wear switch FR
Exhaust brake command

4 RS232C TXD 4 Retarder switch 4
(FRONT TRANSMISSION)
Parking brake auxiliary brake Overrun command (FRONT

5 RS485 (+) 5 5
switch TRANSMISSION)
6 S-NET (+) 6 Lever validation switch 1 6 Brake wear switch RL
7 RS422 TX(-) 7 Lever validation switch 2 7 Brake wear switch RR
8 FLASH SW. (ON/OFF) 8 Brake system filter switch 8 Brake wear switch ML
9 RS422 RX(-) 9 Brake cooling filter switch 9 Brake wear switch MR
10 GND. (SERIAL) 10 æ 10 æ
11 RS485(-) 11 æ 11 æ
12 S-NET (+) 12 æ 12 æ
13 æ 13 æ
14 æ 14 æ
15 æ 15 æ
16 æ 16 æ
17 æ
Starting switch terminal C (engine

18
start signal)
19 æ
20 æ
10-172 HM400-1L
RETARDER CONTROL FUNCTION

RETARDER CONTROL SYSTEM DIAGRAM
Retarder lever control
The operating angle of the retarder lever is detected by the potentiometer and a current corresponding to this is sent to the elec-
tromagnetic 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 (ON/OFF command)
from the transmission controller and actuates the retarder by a fixed amount.
HM400-1L 10-173
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
1. To improve the initial response of the electromagnetic proportional reducing valve, the output (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.
10-174 HM400-1L
HOIST CONTROL FUNCTION

HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function

When the engine is running, the EPC and valve (electromagnetic proportional valve) and selector valve are controlled
according to the operation of the dump control lever and operate the dump body.
2. Lever positioner function

The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of the dump body
reaches the set position of the body position sensor, the lever is returned to the HOLD position.
If the lever is kept at the RAISE position, the RAISE output continues to be given.
3. Body seating speed control

When the dump body is lowered and reaches the position just before it is seated, the opening of the EPC valve is throttled
to control the lowering speed of the dump body and reduce the shock when the dump body comes into contact with the
chassis.
4. Control when starting switch is turned to ON, OFF, or START

Starting switch at ON:
The output is set to HOLD, regardless of the position of the lever.
If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD.
Starting switch at OFF:
The dump body is held in position regardless of the position of the lever.
Engine started:
Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever.
After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
HM400-1L 10-175
5. Float caution function
If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel lights up.
"FLOAT OUTPUT" and "SEATED" → Float caution OFF
"NO FLOAT OUTPUT" or "NOT SEATED" → Float caution ON
6. Reverse inhibit function

The retarder controller judges if it is permissible to travel in reverse or not, and transmits the result of the judgment
through the network to the transmission controller.
"FLOAT OUTPUT" and "SEATED" → Reverse travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" → Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is done to recognize the dump body seating and
the body cylinder stopper condition.
After adjusting the installation of the body potentiometer or after replacing the retarder controller, calibrate in the follow-
ing order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90°C)
A. Lower the dump body completely and run the engine. Change the lever from HOLD to FLOAT and check that the
float caution lamp goes off.
B. Operate the lever to the RAISE position and raise the dump body until it contacts the stopper. Keep the lever at the
RAISE position with the cylinder at the stopper position for at least five seconds.
C. Lower the dump body completely and keep the lever at HOLD for at least five seconds.
D. Run the engine at low idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
lower the dump body completely. Repeat this operation ten times.
E. Run the engine at high idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
10-176 HM400-1L
DIFFERENTIAL LOCK CONTROL FUNCTION

DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM
1. Inter-axle differential lock control

The inter-axle differential lock is actuated automatically, or manually by turning the inter-axle differential lock switch
ON/OFF.
● Manual differential lock:
In low speed ranges (F1, F2, F3, R1, R2) or N, the inter-axle differential lock command is sent when the differential
lock switch is ON.
● Auxiliary braking control (automatic):
The inter-axle differential lock command is sent when the travel speed is more than 35 km/h and the brake is ON.
● Brake ON control (automatic):
The inter-axle differential lock command is sent according to the difference in speed between the front and rear axles
when the brake is ON.
● Control (automatic) when there is variation in transmission output shaft speed:
The inter-axle differential lock command is sent when the variation in the transmission output shaft speed exceeds the
set value.
★ The inter-axle differential lock command is an analog signal and is transmitted to the transmission controller. To
cancel the inter-axle differential lock the transmission controller outputs electric current to the electromagnetic
proportional valve.
2. Left and right differential lock control

Depending on the setting of the left and right differential lock selector switch, one of the following is selected: 1 rear
wheel left and right differential lock ON; 2 front and rear wheel left and right differential lock ON; or 3 front and rear
wheel left and right differential lock OFF.
If 1 or 2 are selected, the differential lock foot switch is pressed, and the speed range is low (F1, F2, F3, R1, R2), the dif-
ferential lock command is output.
HM400-1L 10-177
Inter-axle differential lock output
The inter-axle differential lock command is an analog signal and is transmitted from the retarder controller to the transmission
controller. The transmission controller sends electric current to the electromagnetic proportional valve.
The differential lock clutch is engaged by a pressure proportional to the current
Output specification from retarder controller to transmission controller
The retarder controller output is constant value A when starting to control the differential lock. After A is output, when the
filled signal (signal reporting the completion of filling the electromagnetic proportional valve with oil) comes ON, it provides
an output and angle θ-1 to line B and angle θ-2 to target output line C.
Left and right differential lock output
The left and right differential lock command drives the left and right differential lock solenoid (for front wheels, for rear
wheels) from the retarder controller.
Retarder control lever
The manual retarder potentiometer and lever validation switches 1 and 2 are built into the lever.
The manual retarder potentiometer output is a voltage signal matching the position of the lever and is sent to the retarder con-
troller.
The lever validation switches sends 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 lever 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.
10-178 HM400-1L
STRUCTURE AND FUNCTION BRAKE CONTROL SYSTEM (E-SPEC)
BRAKE CONTROL SYSTEM (E-SPEC)
★ Since the retarder function is not used in E-SPEC, the retarder control lever potentiometer is used to bleed air from the
brake oil circuit.
HM400-1L 10-179
BRAKE CONTROLLER (E-SPEC)

2. Rotary switch
3. Motherboard
4. Case
5. Connector
OUTLINE
The brake controller has the following functions.
1. Overrun prevention, brake control when there is transmission abuse

The electromagnetic proportional valve for the front and rear wheels is controlled based on the command (ON/OFF com-
mand) from the transmission controller and actuates the brake by a fixed amount.
2. Hoist control
This controls the hoist EPC valve (electromagnetic proportional valve) and hoist selector valve (ON/OFF valve) accord-
ing to the position of the dump control lever and actuates the dump body.
3. Differential lock control
A. Inter-axle differential lock control

The differential lock command is output to the transmission controller according to the condition of the machine (dif-
ferential lock switch, travel speed, etc.).
Based on the command from the brake controller, the transmission controller drives the ECMV and actuates the inter-
axle differential lock.
10-180 HM400-1L
B. Left and right differential lock control (Machine with differential lock differential)
Depending on the setting of the left and right differential lock selector switch, if the differential lock foot switch is
ON and the speed range is low (F1, F2, F3, R1, R2), the left and right differential lock is actuated.
4. Exhaust brake control

Based on the command from the transmission controller, the exhaust brake solenoid is driven and the exhaust brake is
actuated.
5. Transmission of network data
A. Brake actuation, float caution, parking brake actuation, exhaust brake actuation, inter-axle differential lock actuation,
accumulator oil pressure drop warning, and other data is transmitted to the monitor panel.
B. The exhaust brake command, overrun prevention, brake command when there is abuse, and other data sent from the
transmission controller are received.
C. The inter-axle differential lock actuation command, reverse inhibit, and other data is transmitted to the transmission
controller.
HM400-1L 10-181
BRC1 BRC2 BRC3A BRC3B

Power source for +24V output Proportional solenoid power
1 1 1 Connector check 1 æ
sensor source +24V
Rear wheel differential lock

2 2 æ 2 æ 2 æ
solenoid
3 Exhaust brake solenoid 3 æ 3 æ 3 æ
4 Brake cut relay (+24V IN) 4 æ 4 æ 4 æ
Accumulator oil pressure

5 æ 5 æ 5 æ 5 (FRONT)
Inter-axle differential lock Sensor power source +5V (hoist

6 Neutral signal 1 6 6 lever potentiometer, body 6 Accumulator oil pressure (REAR)
command
position)
Battery direct power source Accumulator gas pressure

7 7 æ 7 æ 7
input (FRONT)
Front wheel brake

8 GND 8 electromagnetic proportional 8 æ 8 Accumulator gas pressure (REAR)
reducing valve (+)
9 Power source +24V 9 Rear wheel brake electromagnetic 9 æ 9 æ

proportional reducing valve (+)
Front wheel differential lock

10 10 Hoist EPC valve (+) 10 æ 10 æ
solenoid
11 Kick-out solenoid 11 æ 11 æ 11 æ

12 Hoist selector valve 12 12 Transmission front axle speed 12 Hoist lever potentiometer 2
source +24V
13 Brake cut relay 13 æ 13 Transmission output shaft speed 13 Body position sensor
Sensor power source +12V

14 æ 14 14 GND (pulse) 14 Hoist lever potentiometer 1
(pulse)
15 Neutral signal 2 15 æ 15 æ 15 Steering angle potentiometer
Sensor power source +5V Manual retarder lever

16 GND 16
(retarder lever potentiometer)
16 GND (analog) 16 (potentiometer )
17 Power source +24V 17 æ 17 æ
Front wheel brake

reducing valve (-)
Rear wheel brake electromagnetic

19 19 æ
proportional reducing valve (-)
20 Hoist EPC valve (-) 20 æ
21 GND
10-182 HM400-1L
BRC4 BRC5A BRC5B

1 RS422 TX(+) 1 Connector check 2 1 æ
2 RS422 RX(+) 2 Exhaust brake switch 2 Brake wear switch FL
3 RS232 TXD 3 Brake switch 3 Brake wear switch FR
Exhaust brake command

4 RS232C TXD 4 Overrun protection brake switch 4
(FRONT TRANSMISSION)
Parking brake auxiliary brake Overrun command (FRONT

5 RS485 (+) 5 5
switch TRANSMISSION)
6 S-NET (+) 6 Lever validation switch 1 6 Brake wear switch RL
7 RS422 TX(-) 7 Lever validation switch 2 7 Brake wear switch RR
8 FLASH SW. (ON/OFF) 8 Brake system filter switch 8 Brake wear switch ML
9 RS422 RX(-) 9 Brake cooling filter switch 9 Brake wear switch MR
10 GND. (SERIAL) 10 æ 10 æ
11 RS485(-) 11 æ 11 æ
12 S-NET (+) 12 æ 12 æ
13 æ 13 æ
14 æ 14 æ
15 æ 15 æ
16 æ 16 æ
17 æ
Starting switch terminal C (engine

18
start signal)
19 æ
20 æ
HM400-1L 10-183
BRAKE CONTROL FUNCTION

BRAKE CONTROL SYSTEM DIAGRAM
★ Since the retarder function is not used in E-SPEC, the retarder control lever potentiometer is used to bleed air from the
brake oil circuit.
Overrun prevention, brake control when there is transmission abuse
The electromagnetic proportional valve for the front and rear wheels is controlled based on the command (ON/OFF command)
from the transmission controller and actuates the brake by a fixed amount.
10-184 HM400-1L
HOIST CONTROL FUNCTION

HOIST CONTROL SYSTEM DIAGRAM
1. Hoist control function

When the engine is running, the EPC valve (electromagnetic proportional valve) and selector valve are controlled accord-
ing to the operation of the dump control lever and operate the dump body.
2. Lever positioner function

The dump control lever has four positions: RAISE, HOLD, FLOAT, and LOWER.
If the dump control lever is operated to the RAISE position, the dump body is raised, and when the top of the dump body
reaches the set position of the body position sensor, the lever is returned to the HOLD position.
If the lever is kept at the RAISE position, the RAISE output continues to be given.
3. Body seating speed control

When the dump body is lowered and reaches the position just before it is seated, the opening of the EPC valve is throttled
to control the lowering speed of the dump body and reduce the shock when the dump body comes into contact with the
chassis.
4. Control when starting switch is turned to ON, OFF, or START

Starting switch at ON:
The output is set to HOLD, regardless of the position of the lever.
If the engine is not started, even if the hoist lever is operated, the condition remains at HOLD.
Starting switch at OFF:
The dump body is held in position regardless of the position of the lever.
Engine started:
Immediately after the engine is started, the output is set to HOLD, regardless of the position of the lever.
After the lever is moved to the HOLD position, it becomes possible to carry out normal operations.
HM400-1L 10-185
5. Float caution function
If the output is not FLOAT or the dump body is not fully lowered, the float caution lamp on the monitor panel lights up.
"FLOAT OUTPUT" and "SEATED" → Float caution OFF
"NO FLOAT OUTPUT" or "NOT SEATED" → Float caution ON
6. Reverse inhibit function

The brake controller judges if it is permissible to travel in reverse or not, and transmits the result of the judgment through
the network to the transmission controller.
"FLOAT OUTPUT" and "SEATED" → Reverse travel permitted
"NO FLOAT OUTPUT" or "NOT SEATED" → Reverse travel not permitted
7. Calibration function
To absorb any inherent error in the dump body potentiometer, calibration is done to recognize the dump body seating and
the body cylinder stopper condition.
After adjusting the installation of the body potentiometer or after replacing the brake controller, calibrate in the following
order.
Order of dump control calibration (hydraulic oil temperature: 80 - 90°C)
A. Lower the dump body completely and run the engine. Change the lever from HOLD to FLOAT and check that the
float caution lamp goes off.
B. Operate the lever to the RAISE position and raise the dump body until it contacts the stopper. Keep the lever at the
RAISE position with the cylinder at the stopper position for at least five seconds.
C. Lower the dump body completely and keep the lever at HOLD for at least five seconds.
D. Run the engine at low idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
lower the dump body completely. Repeat this operation 10 times.
E. Run the engine at high idle and operate RAISE → FLOAT with the dump body raised to the maximum height, then
10-186 HM400-1L
DIFFERENTIAL LOCK CONTROL FUNCTION

DIFFERENTIAL LOCK CONTROL SYSTEM DIAGRAM
1. Inter-axle differential lock control

The inter-axle differential lock is actuated automatically, or manually by turning the inter-axle differential lock switch
ON/OFF.
● Manual differential lock:
In low speed ranges (F1, F2, F3, R1, R2) or N, the inter-axle differential lock command is activated when the differ-
ential lock switch is ON.
● Auxiliary braking control (automatic):
The inter-axle differential lock command is activated when the travel speed is more than 35 km/h and the brake is
ON.
● Brake ON control (automatic):
The inter-axle differential lock command is activated according to the difference in speed between the front and rear
axles when the brake is ON.
● Control (automatic) when there is variation in transmission output shaft speed:
The inter-axle differential lock command is activated when the variation in the transmission output shaft speed
exceeds the set value.
The inter-axle differential lock command is an analog signal and is transmitted to the transmission controller. To can-
cel the inter-axle differential lock the transmission controller outputs electric current to the electromagnetic propor-
tional valve.
2. Left and right differential lock control

Depending on the setting of the left and right differential lock selector switch, one of the following is selected: 1 rear
wheel left and right differential lock ON; 2 front and rear wheel left and right differential lock ON; or 3 front and rear
wheel left and right differential lock OFF.
If 1 or 2 are selected, the differential lock foot switch is pressed, and the speed range is low (F1, F2, F3, R1, R2), the dif-
ferential lock command is activated.
HM400-1L 10-187
STRUCTURE AND FUNCTION DUMP CONTROL LEVER
DUMP CONTROL LEVER
10-188 HM400-1L
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
HM400-1L 10-189
FUNCTION
● When lever (1) is operated, rod (18) moves up or down according to the amount the lever is operated, and rotates potenti-
ometer (16).
● The amount the control lever is operated (travels) is detected by the potentiometer, and this is sent as a signal voltage to
the controller.
● One potentiometer is installed and sends two related signal voltages as shown in the "Output voltage characteristics"
graph.
OPERATION
DUMP CONTROL LEVER OPERATED TO FLOAT
● When LOWER rod (2) is pushed by lever (1) and moves down, ball
(14) contacts protrusion a of rod (11) during the stroke (before start
of actuation of mechanical detent).
● When rods (2) and (11) are pushed in further, ball (14) is held by
detent spring (12). While pushing retainer (13) up, it escapes to the
outside, and rod (11) passes over protrusion a.
● When this happens, rod (18) on the opposite side is pushed up by
spring (4). Ball (14) is moved to the small diameter side of protru-
sion b of rod (19) by retainer (13) that is held by detent spring (20).
● Even if the lever is released, rod (18) is held in position by the
pushing force of the ball and protrusion b of rod (19), so the lever is
held at the FLOAT position.
DUMP CONTROL LEVER FLOAT CANCELED

When lever (1) is returned from the FLOAT position, it is pushed down
by a force greater than the holding force of rod (19), detent spring (20),
retainer (13), and ball (14).
10-190 HM400-1L
DUMP CONTROL LEVER OPERATED TO LOWER

● When lever (1) is operated further from the FLOAT position, it
moves to the LOWER position.
● Rod (18) is pushed up by the spring (4) in accordance with the
amount lever (1) is operated.
● Lever (17) and rod (19), which are installed to the rotating shaft of
potentiometer (16), are interconnected, so a voltage matching the
up or down movement of the rod is sent from potentiometer (16).
DUMP CONTROL LEVER OPERATED TO RAISE

● When RAISE rod (18) is pushed by lever (1) and moves down, ball
(14) contacts protrusion a of rod (19) during the stroke (before start
of actuation of mechanical detent).
● When rods (18) and (19) are pushed in further, ball (14) is held by
detent spring (20). While pushing retainer (13) up, it escapes to the
outside, and rod (19) passes over protrusion a.
● When this happens, rod (2) on the opposite side is pushed up by
spring (4).
● When an electric current is flowing to solenoid (19), if rod (2) is
pushed up, nut (10) is held in contact with bushing (8).
● As a result, rod (2) is held at the pushed up position, so even if the
lever is released, it is held at the RAISE position.
DUMP CONTROL LEVER RAISE CANCELED

When lever (1) is returned from the RAISE position, it is pushed down
by a force greater than the attraction force of the solenoid.
Or, when the solenoid power source is turned OFF, the RAISE position
is canceled and the lever returns to the N position.
HM400-1L 10-191
STRUCTURE AND FUNCTION PLM-HM
PLM-HM
SYSTEM STRUCTURE
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. Load 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
10-192 HM400-1L
PRINCIPLE OF CALCULATION
1. Outline
The articulate dump truck is suspended by six wheels, a pair each of front, central and rear wheels. The front and rear
wheels are suspended by hydro-pneumatic suspension cylinder. The force Fr, which the rear wheel suspends 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 x Fr
The force Ff = Af x Pf (Af: Suspension cylinder cross section, Pf: Suspension gas pressure)
2. Measurement of weight when empty (calibration)

Drive the empty dump truck with 2nd gear and full throttle for 30 seconds. PLM-HM measures the average of the sus-
pended weight F (empty). PLM-HM uses this value as the weight when empty. The reason why the weight is measured
while the dump truck is traveling is that the frictional resistance of the suspension cylinders must be averaged by extract-
ing and retracting the cylinders by changing the condition of the dump truck. The measured weight 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 suspended force F (empty) when empty from the suspended force F (loaded) when
loaded.
The PLM-HM has three measurement methods in which the timing to measure the payload is different.
Loading (during loading)
Traveling (during traveling)
Dumping (just before dumping)
These three 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 customer’s needs.
Basically, the accuracy of traveling (default setting) is the best for normal conditions.
4. Correction on slope
If the dump truck is loaded on a slope, the measured weight is different from the weight measured on a level ground. To
solve this problem, the longitudinal inclination of the dump track is measured and measured weight is corrected according
to the inclination angle (correction angle of inclination angle: ± 5°).
HM400-1L 10-193
ACCURATE CALCULATION
1. Suspension cylinder length
The PLM-HM calculates the payload by the signal of the suspension cylinder pressure sensors. Please maintain the length
of the suspension cylinder to be within nominal length. Please ask your Komatsu distributor for assistance.
2. Calibration run
Calibration run has to be done when:
● The dump truck is shipped to the site
● The dump body is modified (the weight of the dump truck is changed)
● The gas of the suspension cylinder is maintained
● Periodically (each season)
Calibration run needs a flat, horizontal 100m straight course. If the course is not flat, horizontal or straight, the accuracy of
the calibration run could be in error. This influences the accuracy of the payload measurement.
3. Traveling method
When the traveling method is selected to be stored,
● The accuracy of traveling method depends on the road condition. The more flat the road, the more accurate. Please
maintain the road conditions to get the higher accuracy.
● The accuracy of traveling method depends on the distance of traveling. The longer the distance, the more accurate. It
needs at least 100m for accuracy. The traveling measurement is achieved only when the dump truck speed exceeds
8km/h and the incline of the road is within ±5°. The haul road must be more than 100m which meets the condition
above for Traveling Method.
● Rapid acceleration, braking and steering could affect the accuracy of calculations.
4. Dumping method (same as PLM II for rigid dump truck)

When the dumping method is selected,
● The ground in the dumping area has to be well maintained.
● The incline of the loading spot has be within ±5°. If the incline exceeds ±5°, the accuracy is getting worse.
● Do not hit the dump truck to the wheel stopper too much. If the dump truck hits the wheel stopper too much, the cal-
culated payload might be much higher than the actual payload.
● When the dump truck is stopped, please activate the parking brake and release the service brake or retarder brake.
● Please wait for raising the body until the pitching of the dump truck by braking is suspended. Normally wait for
dumping for three to five seconds to get accuracy after the parking brake is activated and the service brake or retarder
brake is released.
5. Loading method
To keep the accuracy of loading method (including external display lamps)
● The better maintained the ground of loading spot, the more accurate.
● The incline of the loading spot has to be within ±5°. If the incline exceeds ±5°, the accuracy is getting worse.
● Stop the dump truck gently. Do not change the shift to neutral position until the dump truck is stopped completely.
● 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.
● Do not load the material before the dump truck is stopped completely.
● The controller recognizes the loading is finished when the dump truck travels more than 5m after the loading is
started.
10-194 HM400-1L
● The equalizer bar hits the stopper
● If the equalizer bar hits the stopper, the accuracy would become very bad.
● The PLM-HM detects this hit when the empty dump truck stops at the loading stop. When the PLM-HM detects
the equalizer bar to hit the stopper, then the error code "F-FL" is displayed in the PLM-HM load 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" appears, please move the dump truck forward a little bit and stop until the "F-FL" disap-
pears.
● When moving the dump truck forward, please shift the transmission to drive range. When stopping the dump
truck, please shift the transmission to neutral range after the dump truck is completely stopped.
6. Download
The PLM-HM stores the cycle data for 2,900 cycles (normally more than one month operation). If the number of cycles
exceeds 2,900, the newest data is overwritten on the oldest data. Please download the data periodically and clear all the
data before overwriting.
GENERAL LOCATIONS OF LOAD METER

1. Display
2. Communication "receiving" lamp (Rx busy)
3. Communication "transmitting" lamp I (Tx busy)
4. Memory card access lamp (CARD busy) (not used)
5. Mode switch
6. Calibration/clear switch
7. Total/shift switch
8. Light/increment switch
9. Memory card (not used)
10. Cover
★ Communication "transmitting" lamp (3) lights up even when the

communication cable is not connected to a PC or when there is a
defective connection. When not inserting or removing memory card
(9), always keep cover (10) closed.
HM400-1L 10-195
LEFT FACE
★ The switches are adjusted before the machine is shipped. Do not touch any other switch.
10-196 HM400-1L
BASIC FUNCTIONS
1. Power ON
When the power is turned ON, all functions are checked and displayed.
2. Measuring empty weight (calibration)

The weight of the dump truck when empty is measured and used as the calibration data. This data is retained even when
the power is turned OFF.
HM400-1L 10-197
3. Normal operation display
Gearshift lever Load meter External display

Machine Condition Dump truck 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)
estimated display
During loading
Traveling distance OFF
Traveling* Except N Seated
(m)
Stopped N Seated payload (ton) Payload display

When loaded
Total payload**
When dumping N Unseated → Seated OFF
(100 ton)
When an error
--- --- --- See ERROR CODE DISPLAY
occurs
* When a load is less than 50% of correct weight, display shows 0 t.

** The aggregate weight display is shown in units of 100 t (rounded to the nearest 100).
4. External display lamp drive (estimated display)

The chart below shows the payload display level for the external display lamps during the normal operation display. This
threshold can be modified by the key operation in the service check mode.
Lamp color HM400-1
1 Green 18.5 tons and up
2 Yellow 33.3 tons and up
3 Red 38.3 tons and up
The estimated display shows the estimation of the total payload

when one more load is added. The applicable lamp flashes to pre-
vent overload; for example, if current payload is 30 tons and the last
bucket was seven tons, the green lamp is turned on from the table
above. The estimated payload for the next bucket is 37 tons. Then
the yellow lamp is flashed. If the red lamp is flashed, one more
bucket reaches over the red threshold and it will be overloaded.
10-198 HM400-1L
5. Memory content
A. Cycle Data
● The period between one dumping operation and the next dumping operation is taken as one cycle and the data is
recorded.
● The cycle data is 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 cycle, the error message "F-11" is displayed.
B. Engine ON/OFF data

● Each time the engine is 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 "F-12" is displayed. In this case, please download the information and
clear the data.
HM400-1L 10-199
C. Error, warning data
● Each load meter error or warning that is generated or cancelled is recorded.
● The maximum limit in memory for error or warning data is 230 generated/cancelled sets.
6. Forced display of aggregate payload, total number of cycles

By operating the [TOTAL/SFT] PLM-HM switch, it is possible to carry out forcible display of these items. For details, see
the Operation Manual.
7. Operator check mode

By operating the PLM-HM switch, it is possible to carry out the following items. For details, see the Operation and Main-
tenance Manual.
A. Data all clear
B. Machine ID setting
C. Open ID setting
D. Time, date correction
8. Dimming of display portion

It is possible to adjust the brightness of PLM-HM display portion to ten levels with the [LIGHT/INC] switch.
10-200 HM400-1L
9. Downloading saved data
It is possible to download any data recorded in PLM-HM to a PC through a cable (RS232C). For details, see the PC soft-
ware manual provided by Komatsu.
10. Service check mode

By operating the switches of PLM-HM, 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 done.
B. Data all clear (service area)

● This forcibly deletes all the calibration data and analog data, except for the latest calibration data.
★ Before clearing the data, always download 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 PLM-HM and the present recognition condition of
the load meter.
D. Forced initialization
● This forcibly deletes all the data in PLM-HM. PLM-HM becomes just same as the one when the controller is shipped
from the factory.
● Before doing this operation, check the time and date. Always perform this operation with the machine unloaded.
Do not carry out the operation unless necessary.
● If this is carried out, the calibration data is cleared. The inclinometer calibration and calibration run are necessary
to be done again.
HM400-1L 10-201
E. Parameter setting
● This allows to modify the parameter setting.
i. Loading completion travel distance

If the truck moves this distance after loading, PLM-HM recognizes the loading is completed. After the recogni-
tion, the estimate function of the external display doesn’t work. The default setting is 5m.
ii. Loading start threshold

If the calculated payload becomes over this threshold, PLM-HM recognizes the loading is started. And the differ-
ence between the current payload and the last payload is over this threshold, PLM-HM recognizes one more
bucket is loaded. The default is 10%. This default setting must work for eight bucket loadings. 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%).
iii. Payload offset, payload gain

If the calculated payload has an error compared with the payload measured by the scale, this setting and the next
setting (payload gain) allows to adjust the payload.
(The adjusted payload) = (Payload gain) x (Calculated payload) + (Payload offset)
To modify these settings, do not set the value by few data because the data has deviation. To do this, at least five
cycles measurement is necessary.
10-202 HM400-1L
If the error is almost constant according to the payload, "Payload offset" has to be modified. For example, PLM-
HM shows one ton more than the actual for 25.9 ton (70%) payload and 37.0 ton (100%) payload. "Payload gain"
has to be set at "91" ((37.0-25.9)/39.0-26.9)%) and "Payload offset" has to be set as "1.5"(37-0.91*39).
If the error is different according to the payload, "Payload offset" and "Payload gain" has to be modified. For
example, PLM-HM shows one ton more for 70% payload and two tons more for 100% payload, "Payload offset"
has to be set as "-1.5" and "Payload gain" has to be set as "91".
iv. Loading payload offset

If only the calculated payload when loading has an error and the stored payload doesn’t have an error, this setting
allows to adjust the payload display when loading. Normally the ground condition impacts the accuracy of the
payload when loading. Please check the ground condition first.
v. Travel mode min. speed

PLM-HM calculates the payload by averaging the data during the traveling in the traveling mode. Normally the
ground condition is very rough when the vehicle speed is low. If the ground condition is very rough, the accuracy
tends to be worse. PLM-HM averages the data only when the vehicle speed is over this threshold. The default
setting is 8 km/h. This setting is alright for almost all conditions. But if the truck speed is very slow for a long
time and the accuracy of traveling mode is not good enough, this threshold can be modified to less value (5-6 km/
h).
vi. Travel mode max incline

PLM-HM calculates the payload by averaging the data during the traveling in the traveling mode. Normally
when the slope is steep, the accuracy tends to be worse. PLM-HM averages the data only when the slope is less
steep than this threshold. The default setting is 5°. This setting is alright for almost all conditions. But if the
major part of the haul load has more than 5° slope and the accuracy of traveling mode is not good enough, this
threshold can be modified to larger value (7 - 8°).
vii. Green/Yellow/Red lamp threshold

The default setting is 50% for green, 90% for yellow and 105% for red lamp same as the rigid dump truck. The
more tight setting, for example 80% for green, 95% for yellow and 105% for red, enables more precise indica-
tion. We never recommend to make the red lamp threshold to be higher than 105%.
viii. Store mode

PLM-HM has three measurement methods as described before. But only one measurement method is stored and
can be downloaded. Komatsu service has to recommend one method corresponding to the site condition and the
customer needs and set it to PLM-HM controller.
Guideline is:
Traveling mode is the most accurate. Unless there’s a specific reason to choose otherwise, choose traveling
mode.
If the haul road is very rough or very short (less than 200m) and the dumping area is well maintained,
choose dumping mode.
If the customer wants to store the payload displayed during loading, choose loading mode.
ix. Stopper-hit threshold

If the equalizer bar hits the stopper, the accuracy of the payload when loading becomes very bad as described
before. PLM-HM recognizes the hit if the calculated payload is over this threshold when the empty vehicle stops
at the loading spot. The default setting is two tons. If PLM-HM recognizes the hit, the error message "F-FL" is
displayed. If this detection is too sensitive, this threshold can be modified to the higher value (3 ton). But this
causes the failure to detect the hitting. Please take care when the setting is modified.
x. Dump completion threshold

PLM-HM recognizes the dump completion when the payload becomes under this threshold during the dumping.
These is no need to modify this parameter.
HM400-1L 10-203
xi. Stable payload threshold
The calculated payload changes dynamically when loading. PLM-HM waits for the calculation until the calcu-
lated payload becomes stable. This threshold is the one PLM-HM recognizes. This setting (two tons) is alright
for almost all conditions. This impacts the accuracy of the estimated display of the external display lamps. If the
function is strange, this setting can be modified to be less value (one ton). In this case, the time delay to display
the lamps after loading might be longer.
xii. External lamps check mode

This is used for the local installation of PLM-HM. See LOCAL INSTALLATION.
xiii. Machine code

This is used for the local installation of PLM-HM. See LOCAL INSTALLATION. PLM-HM is available for
only HM400-1. "0" means "HM400-1". This setting cannot be modified at this time.
xiv. Payload unit

This is used for the local installation on PLM-HM. See LOCAL INSTALLATION. PLM-HM has two units for
payload display. "0" means "metric ton", "1" means "short ton (US ton)".
xv. Area Code

This is used for the local installation of PLM-HM. See LOCAL INSTALLATION. 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.
xvi. C1, C2, C3, C4

The formulation to calculate the payload is described simply as below.
(Calculated payload) = C1* (Sum of the front suspension cylinder pressure)
+C2* (Sum of the rear suspension cylinder pressure)
+C3* (Incline) + C4(offset)
This setting can modify these parameters. If the accuracy is not good enough even if the parameter tuning for
"payload offset" and "payload gain", this parameter turning is necessary. Do not change these settings without
confirmation to the development center.
10-204 HM400-1L
KEY OPERATION
The chart below describes the key operation tree.
HM400-1L 10-205
10-206 HM400-1L
Key operation and the display includes
A. Power on procedure
B. Normal display
C. Calibration run mode
D. Open ID input
E. Operator check mode
F. Service check mode
A through E are explained in the Operator’s Manual. The key switch operation for F is explained in this section.
SERVICE CHECK MODE

Service check mode has
● Service input signal check mode
● Service calibration data mode
● Service setting mode
● Forcibly initialize mode
A. To enter the service check mode

When the display is in normal display mode, press [MODE]
switch (1) and [LIGHT/INC] switch (2) simultaneously for
more than two seconds, "CHEC" is flashing. This means ser-
vice check mode.
B. To return to the normal display mode

Press [MODE] switch (1), then the display is returned to nor-
mal display.
HM400-1L 10-207
1. Service input signal check mode
A. To enter the service input signal check mode

● When the display is in service check mode ("CHEC" is
flashed), press [CAL/CLR] switch (1) and [TOTAL/SFT]
switch (2) simultaneously for more than two seconds.
● "S.CHE" is flashed. This means the service input signal
check mode.
B. To check the signal input

● Then press [CAL/CLR] switch (1), then "1X.XX" (the far
left digit is flashed) is displayed. The far left digit flashed
shows the number of the item. X.XX means the voltage of
the pressure sensor for the front left suspension cylinder.
● Press [CAL/CLR] switch (1) to see the next content
according to the table at the right. When [CAL/CLR] is
pressed at the last content of power supply voltage
"y27.2", the display is returned to "S.CHE".
● If you want to check the signal again, press [CAL/CLR]
switch (1) again.
C. 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.
10-208 HM400-1L
2. Service calibration data mode
A. To enter the service calibration data mode

● When the display is in the service check mode ("CHEC" is
flashed), press [CAL/CLR] switch (1) for more than two
seconds.
● "CAL0" is flashed. This means the service calibration data
mode.
B. To check the calibration data

● Then press [CAL/CLR] switch (1), then "XX" is dis-
played. XX means the year of the calibration executed.
● Press [CAL/CLR] switch (1) to see the next content
according to the table at right. When [CAL/CLR] switch
(1) is pressed at the last content of calibration payload
[8XX.X], the display is returned to "CAL0".
● If you want to check the signal again, press [CAL/CLR]
switch (1) again.
C. To return to the service check mode

Press [MODE] switch (3) at any process above. "CHEC" is
flashed and the display is returned to the service check mode.
D. To enter the inclinometer calibration mode

● When the display "CAL0" is flashed, press [CAL/CLR]
switch (1) and [TOTAL/SFT] switch (2) simultaneously
for more than two seconds.
● "CAL1" is flashed. See LOCAL INSTALLATION about
the detail of this procedure.
HM400-1L 10-209
3. Service setting mode
A. To enter service setting mode

● When the display is in the service check mode ("CHEC" is
flashed), press [TOTAL/SFT] switch (2) and [LIGHT/
INC] switch (3) simultaneously for more than two sec-
onds.
● "5.5EL" is flashed. Press [CAL/CLR] switch (1) to move
to the next item.
B. To modify the parameter setting

● The far left digit flashed shows the number of the item
selected. The three right digits are the parameter value.
The flashed digit in these three digits is the one which is
selected to be modified.
● Press [TOTAL/SFT] switch (2) to change the digit to be
modified. The flashed digit moves 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".
C. To return to service check mode

Press [MODE] switch (4) then "CHEC" is flashed and the dis-
play is returned to the service check mode.
10-210 HM400-1L
4. Forcibly initialization mode
● Press [CAL/CLR] switch (1), [TOTAL/SFT] switch (2) and
[LIGHT/INC] switch (3) simultaneously for more than two
seconds, then "ACLE" is flashed.
● This means the forcibly initialize mode is ready. Press [CAL/
CLR] switch (1) for more than two 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 initial-
ization is completed.
★ Do not carry out this forcibly initialize mode if not neces-
sary. All the data including the calibration data is cleared.
★ After the execution of this mode, all procedures for local
installation is necessary.
HM400-1L 10-211
SENSORS
1. Pressure sensor
● The pressure sensor is installed at the bottom end of the sus-
pension cylinder for front right/left suspension cylinders and
rear right/left suspension 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) includes a check valve and pre-
vents the pressure from going down.
● The output characteristics of the sensor are as shown in the dia-

gram on the right.
2. Inclinometer
● To carry out compensation on slopes, the inclinometer mea-
sures the longitudinal tilt angle of the chassis. It is installed at
the real frame.
● The output characteristics of the inclinometer are shown in the

diagram on the right.
10-212 HM400-1L
3. Body sensor
● 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 6.3 mm.
4. Articulate angle sensor

Articulate angle sensor detects the articulate angle between the
front and rear frame.
HM400-1L 10-213
ERROR CODE TABLE
10-214 HM400-1L
*1. Please call KOMATSU distributor.

*2. Calibration run cannot be carried out when this has occurred.
*3. Cycle data memory FULL.
a. If more than 2,600 cycles are recorded (less than 300 cycles remaining), L:FULL flashes.
b. If more cycles are recorded, cycles 2,901 and 2,902 are recorded and the older cycle data is deleted to make space to
record the new cycle.
c. If this warning occurs, please download the data and clear all the data (see Data all clear).
*4. Engine ON/OFF data
a. If more than 105 sets are recorded (less than ten sets remain) :E:FULL flashes.
b. If more sets are recorded, sets 116 and 117 are recorded, the oldest ON/OFF data is deleted to make space to record
the new set.
HM400-1L 10-215
c. If this warning occurs, please download the data and clear the all data (see Data all clear).
*5. Equalizer bar hits the stopper
a. If the equalizer bar hits the stopper, the accuracy would become very bad. The PLM-HM detects this hit when the
empty dump truck is stopped at the loading spot.
b. If the error code "F-FLE" is displayed in the PLM-HM display panel, please move the dump truck forward a little bit
and stop the dump truck until the "F-FLE" code disappears. When moving the dump truck forward, please shift the
transmission to drive range. When stopping the dump truck, please shift the transmission to Neutral range after the
dump truck is completely stopped.
*6. Articulated too much 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 worsen. The articulated angle is more than 22.5° (half of full range), this fault code is
activated. If this fault code is activated, please straighten the dump truck.
10-216 HM400-1L
LOCAL INSTALLATION
1. Preparation
A. Before this procedure is carried out, check the suspension length. If the suspension length is out of the nominal range,
charge or discharge the suspension gas and check the suspension length again to be within nominal range (see
HM400-1 Shop Manual). This process is very important to keep the accuracy of PLM-HM. This process has to be
done very carefully.
B. Check the dump body to be empty. If mud is on the dump body or on the chassis, clean it. It impacts the accuracy.
C. The procedure below has to be carried out with installation checklist for articulate dump truck PLM.
D. Calibration needs about 120m straight course with flat and horizontal ground.
E. The more straight, the more accurate. The more flat and horizontal, the more accurate.
F. Park the dump truck on the flat and horizontal ground.
G. Set the articulate straight. Mark the dump truck position on the ground.
H. Turn off the engine.
★ Press switch for 0.5 to one second, do not press switch for more than two seconds.
★ If a mistake is made during switch operation, the MODE switch is effective for recovering in most situations.
★ If you fail in the procedure below, turn off the key and start from the beginning.
2. PLM-HM controller check
A. Turn on the key switch.
B. Display "8.8.:8.8." and buzzer sounds for three seconds.
C. Display "C0:00" (is machine model code = 0[HM400-1]) for about eight seconds. Buzzer sounds one second again
(error detection for F.ICL, and F.CAL).
D. Display "d0:00" (is machine ID = 0) for three seconds.
E. Display "o0:00" (is open ID = 0) for three seconds.
HM400-1L 10-217
F. Display two fault codes, "F.ICL (inclinometer is not calibrated)" and "F.CAL (calibration run is not executed)" alter-
nated. "F-.FL" might be flashed, it’s no problem.
G. If there are other fault codes displayed, please check.
3. External display lamp check
A. Press MODE switch and LIGHT switch simultaneously for more than two seconds. The display flashes "CHEC" (it
means service check mode).
B. Press TOTAL switch and LIGHT switch simultaneously for more than two seconds. The display flashes "S.SEL" (it
means service setting mode).
C. Press CAL switch 15 times. The display is changing from "1._ _5" to "f._ _ 0" ("f" means "external display lamp
check mode"). The symbol " _ " means the "space".
D. Make sure that all the external lamps have flashed (it means error "F-FL" and "F.ICL" to be detected).
E. Press LIGHT switch. The display is "f. _ _ 1". Make sure that only the green lamp has turned on.
F. Press LIGHT switch. The display is "f. _ _ 2". Make sure that only the yellow lamp has turned on.
G. Press LIGHT switch. The display is "f. _ _ 3". Make sure that only the red lamp has turned on.
H. Press LIGHT switch. The display is "f. _ _ 0". Make sure that all the lamps have flashed.
I. If the lamps do not work correctly, please check the connector around the lamps or around the relay circuit.
4. Setting
A. Press CAL switch two times. The display is "J. _ _ 0" ("J" means "payload weight unit setting mode". "0" means met-
ric ton unit). If you want to change the unit to short ton, press TOTAL switch, then the display is "J. _ _ 1" (short ton).
B. Press CAL switch. The display is "L. _ _ 0" ("L" means "area setting mode". "0" means "except Australia"). If the
area is Australia, press TOTAL switch, then the display is "L. _ _ 1" (Australia).
C. Press MODE switch. The display flashes "CHEC" (it means service check mode).
5. Input signal check
A. Start engine.
B. Press CAL switch and TOTAL switch simultaneously for more than two seconds. The display flashes "S.CHE" (it
means service input signal check mode).
C. Press CAL switch. The display is "1X.XX" ("1" is flashed). The right three digits shows the voltage of front left sus-
pension pressure sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or sen-
sor install.
D. Press CAL switch. The display is "2X.XX" ("2" is flashed). The right three digits show the voltage of front right sus-
sor install.
E. Press CAL switch. The display is "3X.XX" ("3" is flashed). The right three digits show the voltage of the rear left sus-
sor install.
10-218 HM400-1L
F. Press CAL switch. The display is "4X.XX" ("4" is flashed). The right three digits show the voltage of the rear right
suspension pressure sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or
sensor install.
G. Press CAL switch. The display is "5X.XX" ("5" is flashed). The right three digits show the voltage of the inclinome-
ter. If the value is out of range, check the wiring or sensor install.
H. Press CAL switch. The display is "6X.XX" ("6" is flashed). The right three digits show the voltage of the backup bat-
tery. Write down the value on the check sheet. If the value is out of range, the backup battery has to be replaced.
I. Press CAL switch. The display is "7X.XX" ("7" is flashed). The right three digits show the voltage of R terminal. The
voltage of R terminal has to be more than 24V, but the maximum value of this display is around 8.3V. If the display is
around 8.3V, it’s OK. If the value is out of range, check the wiring.
J. Press CAL switch. The display is "8X.XX" ("8" is flashed). The right three digits show the voltage of the articulated
sensor. Write down the value on the check sheet. If the value is out of range, check the wiring or sensor install.
K. Press CAL switch six times. The display is "F _ _ 1" ("F" is flashed). The far right digit shows the neutral signal (1 is
neutral, 0 is other). Move the shift lever to "D" range. The display on PLM has to be "F _ _ 0". Return the shift lever
to "N" range. The display on PLM has to be "F _ _ 1". (Check on the check sheet.) If the value is not correct, check
the wiring.
L. Press CAL switch. The display is "H _ _ 1" ("H" is flashed). The far right digit shows the body seated signal (1 is
seated, 0 is not seated). Raise the dump body and the display on the PLM has to be "H _ _ 0". Lower the dump body
and the display on PLM has to become "H _ _ 1". (Check on the check sheet.) If the value is not correct, check the
wiring or sensor install.
M. Press CAL switch. The display is "J _ _ 0" ("J" is flashed). The far right digit shows the velocity. Put the shift lever to
2nd position and move the vehicle with full throttle pedal. The display on PLM has to be around 12 Km/h. (Check on
the check sheet.) If the value is not correct, check the wiring
N. Press the MODE switch. The display flashes "CHEC". Press Mode switch again. Display two error codes, "F.ICL
(inclinometer is not calibrated)" and "F.CAL (calibration run is not executed)" alternately. "F-.FL" might be flashed,
it’s no problem.
6. Inclinometer and articulate sensor calibration
A. Start engine.
B. Inclinometer will be calibrated by measuring two opposite

directions of the vehicle and by averaging sensor inputs of
these two times. The longitudinal incline of the ground must be
canceled. But the more horizontal the ground is, the more accu-
rate. Please find the flat and horizontal area for this calibration.
The accuracy of the inclinometer impacts the accuracy of the
load meter. This process has to be done very carefully.
C. Make sure the articulate is straight. The articulate sensor will

be calibrated as "straight" at this position. Please set the articu-
late to be straight carefully.
D. Press MODE switch and LIGHT switch simultaneously for

more than two seconds. The display flashes "CHEC" (it means
service check mode.
E. Press CAL switch for more than two seconds. The display
flashes "CAL.0" (service calibration data check mode).
HM400-1L 10-219
F. Press CAL switch and TOTAL switch simultaneously for more than two seconds. "CAL.1" (means inclinometer cali-
bration mode) will be displayed and the calibration for inclinometer and articulate sensor are executed for three sec-
onds. "CAL.2" will be flashed after three seconds.
G. Turn the dump truck around and park in the exact same posi-
tion as above, but now facing the opposite direction.
H. Press CAL switch for more than two seconds. "CAL.2" will be
turned on and the calibration for inclinometer and articulate
sensor are calibrated for three seconds again for opposite direc-
tion. "CHEC" will be flashed after the calibration is finished.
I. Press MODE switch. The error code "F.ICL" must be turned

off and only "F.CAL" is flashed. This means the inclinometer
calibration was successfully finished. "F-.FL" might be
flashed, that’s normal.
7. Calibration run
A. The weight of the empty dump truck has to be calibrated because the weight of empty dump truck might be different
by the vessel and attachment options.
B. Park the dump truck on the flat and horizontal ground. Calibration run needs about 120m straight and flat course.
C. Press CAL switch for more than two seconds. "CAL" will be flashed.
D. If you are ready to start, press CAL switch. "CAL" will be lighted up.
E. Shift the transmission to 2nd range.
F. Press throttle pedal full. After the velocity becomes over 9Km/h, the display counts up the elapsed time (seconds).
Calibration run needs 30 second runs.
G. After 30 seconds, the current calculated payload [ton] will be displayed.
H. Stop the dump truck gently, shift the transmission to neutral, turn on the parking brake and release the retarder brake
or service brake. Do not change the transmission to neutral before the dump truck is stopped.
I. Write down the current payload. The displayed payload has to be around 0 ton because the dump truck is empty.
J. 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.
K. Write down the current payload.
L. All external lamps must be turned off.
M. This calibration run has to be done periodically by the customer. Please explain the procedure to the customer.
10-220 HM400-1L
8. Clock set
A. Clock is set for Japanese standard time. The date and the hour might be modified to the local time.
B. Press MODE switch for more than two seconds. The display flashes "oCHE" (it means operator check mode).
C. Press MODE switch. The display is "d000" (it means machine ID).
D. Press MODE switch, The display is "_ _ YZ" ("Z" is flashed, YZ means lower two digits of year. "YZ" for 2003 is
"03").
E. If "Z" has to be corrected, press LIGHT switch, then "Z" is increased.
F. Press TOTAL switch. The display is "_ _ YZ" ("Y" is flashed, YZ means lower two digits of year. "YZ" for 2003 is
"03").
G. If "Y" has to be corrected, press LIGHT switch, then "Y" is increased.
H. Press TOTAL switch. The display is "MM:dd" ("MM" is flashed, MM means month, dd means day).
I. If "MM" has to be corrected press LIGHT switch, then "MM" is increased.
J. Press TOTAL switch. The display is "MM:dd" (dd is flashed, MM means month, dd means day).
K. If "dd" has to be corrected, press LIGHT switch, then "dd" is increased.
L. Press TOTAL switch. The display is "HH.mm" ("HH" is flashed, HH means hour, mm means minutes).
M. If "HH" has to be corrected, press LIGHT switch, then "HH" is increased.
N. Press TOTAL switch. The display is "HH:mm" ("mm" is flashed).
O. If "mm" has to be corrected, press LIGHT switch, then "mm" is increased.
P. Press MODE switch. The display is "A.CLE" ("CLE" is flashed).
Q. Press MODE switch. The clock has to be displayed.
9. Set store mode
A. This PLM-HM has three measurement methods; dumping method, traveling method and loading method. These three
methods are carried out for corresponding stage of each cycle. But only the payload by one method is stored and can
be downloaded. Komatsu service can set which method to be recorded by switch operation in the PLM-HM control-
ler.
B. Each method has its pros and cons. The method to be recorded has to be decided by the site condition and the cus-
tomer’s request.
C. The general guideline is:
i. Traveling method is the most accurate for most sites.
ii. If all the haul road is very rough or the distance of haul road is less than 200m, and the ground of the dumping
area is flat and the incline is less than ± 5°, dumping method can be selected.
iii. If all the haul road is very rough or the distance of haul is less than 200m, and the ground of the dumping area is
not flat or the incline is more than ± 5°, the dumping method cannot be selected.
HM400-1L 10-221
iv. If the customer wants to have the payload data at the loading spot, loading method can be selected.
D. Press MODE switch and LIGHT switch simultaneously for more than two seconds. The display flashes "CHEC" (it
means service check mode).
E. Press TOTAL switch and LIGHT switch simultaneously for more than two seconds. The display flashes "S.SEL" (it
means service setting mode).
F. Press CAL switch 11 times. The display is changing from "1._ _ 5" to "b._ _ 2" ("b" means "store mode setting", "2"
means "traveling method"). If you want to change the store mode, press LIGHT switch. Then the display is changing
to "b._ _ 3" (loading method) to "b._ _1" (dumping method) to "b._ _ 2" (traveling mode). Write down the mode you
set on the check sheet.
G. After the mode is selected, press MODE switch. The display flashes "CHEC" (it means service check mode).
H. Press MODE switch again. The display shows the clock.
10. Trial test
A. Try one cycle including loading, traveling and dumping with almost 100% payload.
B. Please read "To keep the accuracy" in the Operator’s Manual
C. Check the display working correctly as shown in the table below.
Gearshift lever Load meter External display

Machine Condition Dump truck position
position display lamps
Stopped N Seated Time OFF

When empty
Payload display and

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

When loaded
Total payload**
When dumping N Unseated → Seated OFF
(100 ton)
When an error
--- --- --- See ERROR CODE DISPLAY
occurs
* When a load is less than 50% of correct weight, display shows 0 t.

** The aggregate weight display is shown in units of 100 t (rounded to the nearest 100).
D. Download the data. Check the data in the cycle data (payload, dumping time) to be correct.
11. Data clear
A. Press MODE switch for more than two seconds. The display flashes "oCHE" (it means operator check mode).
B. Press MODE switch. The display is "d000" (it means machine ID).
10-222 HM400-1L
C. Press MODE switch. The display is "_ _ YZ" ("Z is flashed, YZ means lower two digits of year. "YZ" for 2003 is
"03").
D. Press MODE switch. The display is "A.CLE" ("CLE" is flashed).
E. Press CAL switch for more than two seconds. The display is "A.CLE" (A.CLE" is flashed).
F. Press CAL switch for more than two seconds. The display is "A.CLE" ("A.CLE is lighted up). All clear of the cycle
data and fault history will be started.
G. After all clear, the display becomes clock set.
H. Turn off engine.
HM400-1L 10-223
10-224 HM400-1L
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

STANDARD VALUE TABLE FOR CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
STANDARD VALUE TABLE FOR ELECTRICAL COMPONANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
MEASURING EXHAUST SMOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
MEASURING EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
MEASURING CRANCASE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
MEASURING ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
MEASURING BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
MEASURING FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
BLEEDING AIR FROM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
ADJUSTING ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
ADJUSTING ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
ADJUSTING REFRIGERANT COMPRESSOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TESTING TORQUE CONVERTER STALL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
MEASURING POWER TRAIN OIL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
MEASURING POWER TRAIN MAIN RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
MEASURING TORQUE CONVERTER “INLET” OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
MEASURING TORQUE CONVERTER “OUTLET” OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
MEASURING TORQUE CONVERTER “LOCK-UP” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . 20-32
MEASURING TRANSMISSION “LO” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
MEASURING TRANSMISSION “HI” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
MEASURING TRANSMISSION “1ST” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
MEASURING TRANSMISSION “2ND” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
MEASURING TRANSMISSION “3RD” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
MEASURING TRANSMISSION “R” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
MEASURING INTER-AXLE “DIFFERENTIAL LOCK” CLUTCH PRESSURE . . . . . . . . . . . . . . . . . . . 20-35
TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE . . . . . . . . . . . . . . . . . . . . 20-36
TESTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
TESTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
TESTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
ADJUSTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
ADJUSTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
ADJUSTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
ADJUSTING TRANSMISSION SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
TESTING AND ADJUSTING BRAKE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
MEASURING ACTUATION PRESSURE ON PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID . . . . . . . . . . . . . . . . . . . 20-44
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
TESTING BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
TESTING BRAKING PERFORMANCE OF FOOT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
HM400-1L 20-1 1
TESTING AND ADJUSTING TABLE OF CONTENTS
TESTING PARKING BRAKE BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
BLEEDING AIR FROM BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE . . . . . . . . . . . . . . . . . . . . 20-48
BLEEDING AIR FROM WHEEL BRAKE PORTION OF FOOT BRAKE CIRCUIT . . . . . . . . . . . . . . . . 20-49
BLEEDING AIR FROM PARKING BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC AND PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
CHECKING BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
CHECKING BRAKE PAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51
ADJUSTING PAD CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
RELEASING EMERGENCY PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
MEASURING STEERING RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-54
ADJUSTING STEERING RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
TESTING AND ADJUSTING SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
CHECKING CYLINDER LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
RELEASING NITROGEN GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
ADJUSTING OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-57
CHARGING WITH NITROGEN GAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
ADJUSTING CYLINDER LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-59
TILTING THE CAB UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
PREPARATORY WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
TILTING CAB UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
USING EXTERNAL CRANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
HOLDING CAB IN POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
LOWERING CAB DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
TESTING DUMP MAIN RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
ADJUSTING DUMP MAIN RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-62
MEASURING DUMP PILOT RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
ADJUSTING DUMP PILOT RELIEF OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-63
ADJUSTING BODY POSITIONER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
CHECKING SENSOR OUTPUT/INPUT VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
ADJUSTING LINK LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-64
CALIBRATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-65
HANDLING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-66
ADJUSTING TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
SETTING ROTARY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
ADJUSTING TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-67
ESCAPE METHOD FOR ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-68
ADJUSTING MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
FUNCTIONS OF MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-76
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . 20-76
FLOW OF MODES AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-77
OPERATION AND DISPLAYS FOR OPERATOR MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-79
SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-87
20-2 1 HM400-1L
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
STANDARD VALUE TABLE
FOR ENGINE
Engine SAA6D140E-3
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idling 2,200 ± 50 2,200 ± 50
Engine speed Low idling rpm 725 ± 25 725 ± 25
Rated speed 2,000 ± 50 2,000 ± 50
Air supply kPa Min. 133.32 Min. 112
At rated speed
(boost pressure) (psi) (19.3) (16.2)
Whole speed range [ambient ºC Max. 650 Max. 700
Exhaust temperature
temperature: 20ºC (68ºF)] ºF (1202) (1292)
At sudden acceleration Bosch Max. 4.0 Max. 6.0
Exhaust gas color
At high idling index Max. 1.0 Max. 2.0
Valve clearance Intake valve mm 0.35 (0.01) –
(normal temperature) Exhaust valve (in) 0.57 (0.22)) –
Oil temp. 40 – 60ºC kPa
4.12 (0.6) 2.84 (0.4)
Compression pressure (104 – 140ºF) (psi)
[200 - 250] [200 - 250]
[engine speed] [rpm]
Coolant temperature: Within
kPa 1.96 3.92
Blow-by pressure operating range
(psi)} (0.3) (0.6)
At rated output
Coolant temperature:
Within operating range
0.34 – 0.54 Min. 0.21
At high idling
(49 - 78) (30)
SAE30 or SAE15W-40 oil
MPa 0.29 – 0.49 Min. 0.18
Oil pressure SAE10W oil
(psi) (42 - 71) (26)
At low idling
0.12 (17) Min. 0.07 (10.2)
SAE30 or SAE15W-40 oil
0.10 (15) Min. 0.07 (10.2)
SAE10W oil
Whole speed range
Oil temperature ºC (ºF) 80 – 110 (176 - 230) Max. 120 (248)
(inside oil pan)
13 – 15 (1.0 - 1.2) 13 – 15 (1.0 - 1.2)
Deflection when pressed with finger When new When new
Fan belt tension force of approximately mm (in) 17 – 19 (1.2 - 1.3) 17 – 19 (1.2 - 1.3)
98 Nm (72 ft/lbs) When adjusting When adjusting
tension tension
Deflection when pressed with finger
Alternator belt tension force of approximately mm (in) 13 – 16 (1.0 - 1.2) 13 – 16 (1.0 - 1.2)
98 Nm 72 ft/lbs) (for 1 belt)
Deflection when pressed with finger
Refrigerant compressor
force of approximately mm (in) 10 (0.2)) 10 (0.2))
belt tension
58.8 Nm (43 ft/lbs)
HM400-1L 20-3 1
12
FOR CHASSIS
Standard value
Service limit
Cat. Item Measurement conditions Unit for new
value
machine
Starting to 17.7 ± 4.9 17.7 ± 4.9
Accelerator pedal
Point 150 mm (6.0 in) depress N (4.0 ± 1.1) (4.0 ± 1.1)

Operating effort
from pedal fulcrum Fully (lbs) 42.2 42.2
depressed (9.5) (9.5)
Point 150 mm (6.0 in) from pedal mm 45 ± 5 45 ± 5
Travel
fulcrum (in) (2 ± 0.2) (2 ± 0.2)
Torque converter lock- Engine coolant
- 1,400 ± 50 1,400 ± 50
up actuation speed temperature: Within
Torque converter lock- operating range Brake ON 950 ± 50 950 ± 50
up cancel speed Torque converter oil Brake OFF 850 ± 50 850 ± 50
temperature: Within rpm
Torque converter stall
operating range
speed
Hydraulic - 1,809 ± 100 1,809 ± 100
oil temperature: 45 -
Engine
55ºC (113 - 131ºF)

Transmission shift-up Engine coolant tempera-
2,150 ± 50 2,150 ± 50
Engine speed
speed ture: Within operating Normal

Transmission shift- range mode
Torque converter oil tem- 1,250 ± 50 1,250 ± 50
down speed
Transmission shift-up perature: Within operat-
ing range rpm 2,200 ± 50 2,200 ± 50
speed
Hydraulic oil Brake mode
Transmission shift-
temperature: 45 - 55ºC 1.550 ± 50 1.550 ± 50
down speed
(113 - 131ºF)
Transmission down- Brake mode: Accelera-
shift inhibit speed - 1.550 ± 50 1.550 ± 50
tor OFF or brake ON
Overrun prevention
2,600 ± 10 2,600 ± 10
actuation speed
- rpm
Overrun prevention
2,350 ± 10 2,350 ± 10
cancel speed
Gearshift lever
N 21.6 ± 3.9 Max. 19.6

Operating effort Center of lever grip (lbs) (6 ± 1) (Max. 5.2)
Between each position
Travel mm (in) 24.5 ± 1 (1±.04) 24.5 ± 1 (1±.04)
Torque converter oil 2.62 ± 0.15 2.62 ± 0.15
Low idling
Power train main relief temperature: Within MPa (380 ± 22) (380 ± 22)
pressure operating range (psi) 2.33 ± 0.15 2.33 ± 0.15
Power train
High idling
Gearshift lever: N (lbs) (334 ± 22) (334 ± 22)
Torque converter inlet 0.90 ± 0.10 0.90 ± 0.10
Oil pressure
port pressure (131 ± 15) (131 ± 15)

Torque converter oil temperature:
Torque converter MPa 0.59 ± 0.10 0.59 ± 0.10
outlet port pressure (psi) (86 ± 15) (86 ± 15)
Engine speed: High idling
Torque converter lock- 1.81 ± 0.15 1.81 ± 0.15
up clutch pressure (263 ± 22) (263 ± 22)
Transmission Lo 2.55 ± 0.15 2.55 ± 0.15
clutch pressure MPa (370 ± 22) (370 ± 22)
Transmission Hi clutch (psi) 2.55 ± 0.15 2.55 ± 0.15
pressure (370 ± 22) (370 ± 22)
20-4 1 HM400-1L

Standard value
Service limit
Cat. Item Measurement conditions Unit for new
value
machine
Transmission 1st 2.55 ± 0.15 2.55 ± 0.15
clutch pressure (370 ± 22) (370 ± 22)
Transmission 2nd 2.55 ± 0.15 2.55 ± 0.15
clutch pressure (370 ± 22) (370 ± 22)
Transmission 3rd 2.45 ± 0.15 2.45 ± 0.15
Oil pressure
clutch pressure Torque converter oil temperature: (355 ± 22) (355 ± 22)
MPa
Transmission R clutch Within operating range 2.55 ± 0.15 2.55 ± 0.15
(psi)
pressure Engine speed: High idling (370 ± 22) (370 ± 22)
Inter-axle differential 2.55 ± 0.15 2.55 ± 0.15
lock clutch pressure (370 ± 22) (370 ± 22)
Transmission
0.20 ± 0.04 0.20 ± 0.04
lubricating pressure
(29 ± 6) (29 ± 6)
(reference)
7.2 ± 5% 7.2 ± 5%
F1
Power train
4 ± 5% 4 ± 5%
11.0 ± 5% 11.0 ± 5%
F2
7 ± 5% 7 ± 5%
16.9 ± 5% 16.9 ± 5%
F3 Flat ground 11± 5% 11± 5%
Engine coolant temperature: Within
Travel speed
25.8 ± 5% 25.8 ± 5%
F4 operating range
km/h 16 ± 5% 16 ± 5%
(mph) 39.4 ± 5% 39.4 ± 5%
F5 Within operating range
24 ± 5% 24 ± 5%
Dump body: Unloaded
Travel resistance: 3.3% 58.6 ± 5% 58.6 ± 5%
F6
36 ± 5% 36 ± 5%
7.4 ± 5% 7.4 ± 5%
R1
5 ± 5% 5 ± 5%
17.5 ± 5% 17.5 ± 5%
R2
11 ± 5% 11 ± 5%
Standard tire: 29.5 - R25 MPa 0.372 0.372
Tire inflation pressure
Dump body: Unloaded (psi) (54) (54)
25 ± 2.5
25 ± 2.5
Differential lock
Front differential Engine speed: High idling (3626 ± 363)

Oil pressure
(3626 ± 363)
Left and right differential lock switch:
MPa
ON
(psi) 25 ± 2.5 25 ± 2.5
Center differential Left and right differential lock pedal:
(3626 ± 363) (3626 ± 363)
Depressed
25 ± 2.5 25 ± 2.5
Rear differential
(3626 ± 363) (3626 ± 363)
N Max. 294 Max. 294
Brake pedal
Operating effort
(lbs) (Max. 66) (Max. 66)
Tip of pedal
mm 40 ± 5 40 ± 5
Travel
Brakes
(in) (2 ± 0.2) (2 ± 0.2)

N 5.9 – 9.8 3.0 – 14.7
lever (q1)
Retarder
Operating effort
(lbs) (1.4 – 2.2) (1 – 3.3)
Point 10 mm from tip of lever
Travel mm (in) 78 (255) 78 (255)
★ Not installed in E-SPEC.
HM400-1L 20-5 1

Standard value Service limit
Cat. Item Measurement conditions Unit
for new machine value
Charge valve cut-in 11.77 11.77
pressure Wheel brake actuation pressure: (1697) (1697)
Actuation pressure when brake is
Charge valve cut-out operated for first time after engine is 20.59 20.59
pressure stopped (2986) (2986)
Oil pressure
Wheel brake actuation Drop in wheel brake actuation pressure: 4.9 ± 0.49 4.9 ± 0.49
pressure Drop in pressure 5 minutes after MPa (711 ± 71) (711 ± 71)
Drop in wheel brake specified oil pressure (psi) Max. 40.49 Max. 40.49
actuation pressure 4.9 MPa (711 psi) is applied (Max. 5873) (Max. 5873)
Parking, exhaust brake actuation
Parking brake 3.92 ± 0.25 3.92 ± 0.25
pressure: Engine at high idling
actuation pressure (569 ± 36) (569 ± 36)
Parking brake switch: ON
Exhaust brake Exhaust brake switch: ON 0.59 ± 0.10 0.59 ± 0.10
actuation pressure (86 ± 15) (86 ± 15)
Foot brake braking
1,510 1,510
performance
Brakes
Retarder brake braking Engine speed: High idling

Wheel brake
performance Gearshift lever: D rpm

Overrun protection Torque converter stall speed 1,400 1,400
brake braking
performance
Flat, dry road surface
Foot brake braking m
When load is 36.3 t Max. 22.3 (73) Max. 22.3 (73)
distance (ft)
Travel speed: 32 km/h (20 mph)
Engine at high idling
Parking brake
Braking performance Gearshift lever: D rpm 1,400 1,400

Engine stall speed
When load is 36.3 t
Braking slope angle % Min. 25 Min. 25
Slope angle (sin q)
9 ± 1% downhill slope
Emergency brake braking m
When load is 36.3 t Max. 102 (335) Max. 102 (335)
distance (ft)
Travel speed: 50 ± 3 km/h (30 ± 2)
Engine speed: Low idling N Max. 29.4 Max. 35.3
Operating effort
Gearshift lever: N (stopped) (lbs) (Max. 7) (Max. 8)
Measure at circumference of steering
Steering wheel
Play mm (in) Max. 150 (6) Max. 150 (6)

wheel
No. of turns Turns 4.0 ± 0.4 4.0 ± 0.6
Operating effort: When turning at 10
rpm
Steering
Play: Until point where tires start to

Turning time move Sec. Max. 4 Max. 5
No. of turns: Lock - lock
Turning time: Lock - lock
Hydraulic oil temperature: 45 - 55ºC
MPa 20.59 20.59
Steering relief pressure (113 - 131ºF)
(psi) (2986) (2986)
Installed length (a) Horizontal road surface mm (in) 163 ± 5 (6.4± 0.2) 163 ± 5 (6.4± 0.2)
Front
Dump body: Unloaded

Suspension cylinder
MPa 3.92 ± 0.15 3.92 ± 0.15

Pressure
(psi) (569 ± 22) (569 ± 22)
Installed length (a) mm (in) 101 ± 5 (4 ± 0.2) 101 ± 5 (4 ± 0.2)
Rear
MPa 3.92 ± 0.15 3.92 ± 0.15

Pressure
(psi) (569 ± 22) (569 ± 22)
20-6 1 HM400-1L
Machine model HM400-1

Standard value Service limit
Cat. Item Measurement conditions Unit
for new machine value
HOLD Max. 29.4 Max. 35.3
RAISE (Max. 7) (Max. 7)
RAISE Must return smoothly when engine is
HOLD at high idling
HOLD Max. 29.4 Max. 35.3
Engine stopped FLOAT N (Max. 7) (Max. 8)
Dump lever operating effort
Center of grip FLOAT (lbs) Max. 29.4 Max. 35.3
HOLD (Max. 7) (Max. 8)
FLOAT Max. 29.4 Max. 35.3
LOWER (Max. 7) (Max. 8)
LOWER Must return smoothly when engine is
FLOAT at 2000 rpm
Lifting time Hydraulic oil temperature: 70 - 90ºC 12 ± 1.5 12 ± 1.5
(158 - 194ºF)
Sec.
Lowering time Engine speed: High idling Max. 13 Max. 13
Lowering time when operating FLOAT
Dump
Dump body

(158 - 194ºF)
Hold at point where No. 2 cylinder is
Hydraulic drift extended 100 mm Sec. Max. 85 Max. 170
Engine stopped
Downward movement at tip of dump
body over 5 minutes
20.59 ± 0.49 20.59 ± 0.49
Dump main relief pressure (113 - 131ºF)
(2986 ± 71) (2986 ± 71)
3.4 ± 0.49 3.4 ± 0.49
(113 - 131ºF) MPa
(493 ± 71) (493 ± 71)
Engine speed: High idling (psi)
Dump pilot relief pressure Hydraulic oil temperature: 45 - 55ºC
(113 - 131ºF) 2.6 ± 0.49 2.6 ± 0.49
Engine speed: High idling (377 ± 71) (377 ± 71)
(Reference value)
HM400-1L 20-7 1
FOR ELECTRICAL COMPONANTS

Connector Inspection Measurement
System Name of component Judgement table
No. method conditions
If the condition is as shown in the table below, 1) Insert T-adapter to
it is normal AS1.
2) Turn ignition switch
Potentiometer
ON.
Between (3) and (1) 4.6 – 5.4 V
Between (2) and (3) 0.3 – 4.5 V
Acceleration pedal Measure Switch

AS1
(throttle sensor) voltage Potentiomet
Pin er voltage Voltage
Between (5) Max. 0.446V Max. 1V

and (4) Min. 0.446V 15 – 30V
Between (6) Max. 0.446V 20 – 30V
and (4) Min. 0.446V Max. 1V
If the condition is as shown in the table below, 1) Turn ignition switch

it is normal OFF.
Engine Ne rotation Measure
NE (male) Between (1) and (2) 85 – 210 2) Disconnect NE.
sensor resistance
Between (1)(2) and ground Min. 1MΩ

it is normal OFF.
Engine G rotation Measure
G (male) Between (1) and (2) 1.4kΩ – 3.5kΩ 2) Disconnect G.
sensor resistance
Engine controller system

it is normal OFF.
Resistance 2) Disconnect PSL.
Position Engine value
Engine oil low-pressure PSL Measure
switch (terminal) resistance Engine Max. 1Ω
Between stopped
switch terminal
and ground At 600 rpm and Min. 1 MΩ
above

it is normal OFF.
Resistance 2) Disconnect PSH.
Position Engine value
Engine oil high-pressure PSH Measure
switch (terminal) resistance Engine Max. 1Ω
Between stopped
switch terminal
and ground At 1,300 rpm Min. 1 MΩ
and above

it is normal OFF.
Engine coolant low- Measure
TWL (male) Between (1) and (2) 9kΩ – 0.3kΩ 2) Disconnect TWL.
temperature sensor resistance

it is normal OFF.
Engine coolant high- TWH Measure
Between (1) and (2) 90kΩ – 3.5kΩ 2) Disconnect TWH.
temperature sensor (male) resistance

it is normal OFF.
Fuel temperature Measure
THL (male) Between (1) and (2) 9kΩ – 0.3kΩ 2) Disconnect THL.
sensor resistance
20-8 1 HM400-1L


it is normal OFF.
2) Disconnect OF.
Position Oil filter Resistance
Engine oil filter clogging OF Measure value
switch (terminal) resistance
Between When normal Max. 1 Ω
switch terminal
and ground When clogged Min. 1 MΩ

it is normal OFF.
2) Disconnect OL.
Pin Oil level Resistance
value
Measure
Engine oil level switch OL (male) When normal Max. 1 Ω
resistance Between (1)
and ground When low Min. 1 MΩ

it is normal PIM.
Measure
Boost pressure sensor PIM (male) Between (1) and (3) 4.6 – 5.4 V 2) Turn ignition switch
voltage
Between (2) and (3) 0.3 – 4.7 V ON.

it is normal PFUEL.
Common rail fuel PFUEL Measure
pressure sensor (male) voltage Between (1) and (3) 4.6 – 5.4 V
Between (2) and (3) 0.3 – 4.7 V ON.
If the condition is as shown in the table below, 1) Turn ignition

it is normal switchOFF.
PCV1 Measure
Fuel supply pump PCV1 Between (1) and (2) 2.3 – 5.3 Ω 2) Disconnect PCV1.
(male) resistance

it is normal OFF.
PCV2 Measure
Fuel supply pump PCV2 Between (1) and (2) 2.3 – 5.3 Ω 2) Disconnect PCV2.
(male) resistance
Between (1)(2) and ground Min. 1 MΩ

it is normal OFF.
Measure
No. 1 injector solenoid CN1 (male) Between (1) and (2) 0.4 – 1.1 Ω 2) Disconnect CN1.
resistance

it is normal OFF.
Measure
resistance

If the condition is as shown in the table below,
it is normal
OFF.
Measure
No. 3 injector solenoid CN3 (male) 2) Disconnect CN3.
resistance Between (1) and (2) 0.4 – 1.1 Ω

it is normal OFF.
Measure 2) Disconnect CN4.
No. 4 injector solenoid CN4 (male) Between (1) and (2) 0.4 – 1.1 Ω
resistance
HM400-1L 20-9 1


it is normal OFF.
Measure
resistance

it is normal OFF.
Measure
resistance

it is normal SF1.
Pin Gearshift lever position and 2) Turn ignition switch
voltage ON.
Between (1) 20 – 30 V
and (2)
Between (3) R2: 20 – 30 V Other than
and (2) R2: Max. 1 V
Between (4) R1: 20 – 30V Other than
and (2) R1: Max. 1V
Between (5) N: 20 – 30 V Max. 1than
Other N:
and (2) V
Measure Between (6) D: 20 – 30 V Other than D:
Gearshift lever SF1 and (2) Max. 1 V
voltage
Between (7) 5: 20 – 30 V Other than 5:
and (2) Max. 1 V
and (2) Max. 1 V
and (2) Max. 1 V
and (2) Max. 1 V
Transmission controller system
and (2) Max. 1 V

Between (12) HOLD: 20 – Canceled:
and (2) 30 V Max. 1 V

it is normal AS2.
Acceleration pedal Measure 2) Turn ignition switch
AS2 Between (1) and (3) 4.5 – 5.4 V
(throttle sensor) voltage ON.
Between (2) and (3) 1.0 – 4.0 V

it is normal OFF.
EREV Measure 2) Disconnect EREV.
Engine speed sensor Between (1) and (2) 500 – 1000Ω
(male) resistance

it is normal OFF.
Resistance
2) Disconnect T11.
Air cleaner clogging Measure Pin Air cleaner value
T11 (male)
sensor resistance
Between (1) When normal Max. 1 Ω
and (2) When clogged Min. 1 MΩ

it is normal OFF.
Radiator Resistance 2) Disconnect T01.
Radiator coolant level Measure Pin coolant level value
T01 (male)
switch resistance
and (2) When low Min. 1 MΩ
20-10 1 HM400-1L

If the condition is as shown in the table below, 1) Disconnect
it is normal terminal R.
Position Engine Voltage 2) Start engine.
R, E Measure Between R Mid-range
Alternator speed or 27.6 – 29.5 V
terminal voltage and E above
★ If the battery is old, or after starting in
cold areas, the voltage may not rise for
some time.

it is normal OFF.
2) Disconnect T08.
Pin Fuel level Resistance
Measure value
Fuel level sensor T08 (male)
resistance
Between (1) Full Max. 12 Ω
and (2) Empty 74 – 100 Ω

it is normal OFF.
Transmission input Measure
N1 (male) Between (1) and (2) 500 – 1000 2) Disconnect N1.
shaft speed sensor resistance
Between (2) and (3) Min. 1 MΩ

Transmission it is normal OFF.

Measure
intermediate shaft N2 (male) Between (1) and (2) 500 – 1000 2) Disconnect N2.
resistance
speed sensor Between (1)(2) and ground Min. 1 MΩ

it is normal OFF.
Transmission output Measure
N3 (male) Between (1) and (2) 500 – 1000 Ω 2) Disconnect N3.
shaft R speed sensor resistance

it is normal OFF.
Resistance 2) Disconnect L/U-
Pin Clutch SW.
Lock-up clutch ECMV L/U-SW Measure value
fill switch (male) resistance When
Between (1) disengaged Min. 1 MΩ
and ground
When engaged Max. 1 Ω

it is normal OFF.
Resistance 2) Disconnect R-SW.
Pin Clutch
R clutch ECMV fill R-SW Measure value
switch (male) resistance When
and ground

it is normal OFF.
Resistance 2) Disconnect H-SW.
Pin Clutch value
Hi clutch ECMV fill H-SW Measure
and ground
HM400-1L 20-11 1

it is normal OFF.
Pin Clutch Resistance 2) Disconnect L-SW.
Lo clutch ECMV fill L-SW Measure value
switch (male) resistance When Min. 1 MΩ
Between (1) disengaged
and ground

it is normal OFF.
Resistance
2) Disconnect 1-SW.
1st clutch ECMV fill 1-SW Measure Pin Clutch value
and ground

it is normal OFF.
Resistance 2) Disconnect 2-SW.
Pin Clutch value
2nd clutch ECMV fill 2-SW Measure
switch (male) resistance When Min. 1 MΩ
Between (1) disengaged
and ground

it is normal OFF.
Resistance 2) Disconnect 3-SW.
3rd clutch ECMV fill 3-SW Measure Pin Clutch value
and ground

it is normal OFF.
Resistance 2) Disconnect D/L-
Differential lock clutch D/L-SW Measure Pin Clutch value SW.
ECMV fill switch (male) resistance When
and ground

it is normal OFF.
Torque 2) Disconnect TC-SE.
Pin converter oil Resistance
Torque converter oil TC-SE Measure value
temperature
Between (1) 25 ºC (77ºF) 37kΩ – 50kΩ
and (2) 100 ºC (212ºF) 3.5kΩ – 4.0kΩ

it is normal TC-INT.
Torque converter oil TC-INT Measure
Between (2) and (1) 20 – 30 V 2) Turn ignition switch
pressure sensor (male) voltage
Between (3) and (1) 0.8 – 2.0 V ON.

it is normal OFF.
Transmission Resistance 2) Disconnect T03.
Transmission oil filter Measure Pin oil filter value
T03 (male)
clogging switch resistance Max. 1 Ω
Between (1) When normal
20-12 1 HM400-1L

it is normal OFF.
Pin Transmission Resistance 2) Disconnect LUB-T.
Transmission valve oil LUB-T Measure oil temperature value
and (2) 100 ºC (212ºF) 3.5kΩ – 4.0kΩ

it is normal OFF.
Hydraulic oil Resistance
2) Disconnect T06.
Hydraulic tank oil level Measure Pin level value
T06 (male)
switch resistance
and (2) When low Min. 1 MΩ

it is normal OFF.
Hydraulic oil Resistance 2) Disconnect T05.
Hydraulic oil filter Measure Pin filter value
T05 (male)
clogging switch resistance Max. 1 Ω
Between (1) When normal

OFF.
it is normal
Steering oil Resistance 2) Disconnect T04.
Steering oil Measure Pin temperature value
T04 (male)
temperature switch resistance Max. 1 Ω
Between (1) 25 ºC (77ºF)
and ground 100 ºC (212ºF) Min. 1 MΩ

it is normal OFF.
Brake oil Resistance 2) Disconnect T15.
Front brake oil Measure Pin temperature value
T15 (male)
and (2) 100 ºC (212ºF) 3.5kΩ – 4.0kΩ

it is normal OFF.
Center brake oil Measure Pin temperature value
T14 (male)
and (2) 100 ºC (212ºF) 3.5kΩ – 4.0kΩ

it is normal OFF.
Rear brake oil Measure Pin
T13 (male) temperature value
and (2) 100 ºC (212ºF) 3.5kΩ – 4.0kΩ

it is normal T10.
Measure Between (1) and (3) 11 – 13 V 2) Turn ignition switch
Inclination sensor T10 (male) ON.
voltage 1.4 – 4.6 V
Between (2) and (3) (when horizontal:
2.9 – 3.1 V)
HM400-1L 20-13 1


it is normal OFF.
Lock-up clutch ECMV L/U-PS Measure 2) Disconnect L/U-
Between (1) and (2) 5 – 15 Ω
solenoid (male) resistance PS.

it is normal OFF.
R clutch ECMV R-PS Measure 2) Disconnect R-PS.
Between (1) and (2) 5 – 15 Ω
solenoid (male) resistance

it is normal OFF.
Hi clutch ECMV H-PS Measure
solenoid (male) resistance Between (1) and (2) 5 – 15 Ω 2) Disconnect H-PS.


it is normal OFF.
Lo clutch ECMV Measure
L-PS (male) Between (1) and (2) 5 – 15 Ω 2) Disconnect L-PS.
solenoid resistance

it is normal OFF.
1st clutch ECMV Measure
1-PS (male) Between (1) and (2) 5 – 15 Ω 2) Disconnect 1-PS.
solenoid resistance

it is normal OFF.
2nd clutch ECMV Measure
solenoid resistance

it is normal OFF.
3rd clutch ECMV Measure
solenoid resistance

it is normal OFF.
Differential lock clutch D/L-PS Measure
Between (1) and (2) 5 – 15 Ω 2) Disconnect D/L-
ECMV solenoid (male) resistance
Between (1)(2) and ground Min. 1MΩ PS.
Retarder controller system (q1)

it is normal
OFF.
Transmission output Measure
FE1 (male) 2) Disconnect FE1.
shaft F speed sensor resistance Between (1) and (2) 500 – 1000 Ω

1) Disconnect B39.
it is normal 2) Start engine.
Pin Differential lock Resistance

oil pressure value
Front differential lock Measure
B39 (male) Max. 0.39 MPa
oil pressure switch resistance (Max. 57 psi) Min. 1 MΩ
Between (1)
and (2) Min. 0.59 MPa
(Min. 85 psi) Max. 1 Ω
20-14 1 HM400-1L

If the condition is as shown in the table below, 1) Disconnect B40.
Pin Differential lock Resistance
oil pressure value
Rear differential lock oil Measure
pressure switch resistance (Max. 57 psi) Min. 1 MΩ
Between (1)

it is normal B25.
Front accumulator oil Measure
B25 (male) Between (2) and (1) 20 – 30V 2) Turn ignition switch
pressure sensor voltage
Between (3) and (1) 1.8 – 3.5 V ON.

Rear accumulator oil Measure it is normal B24.
B24 (male) Between (1) and (2) 20 – 30 V 2) Turn ignition switch
pressure sensor voltage
Between (1)(2) and ground 1.8 – 3.5 V ON.
If the condition is as shown in the table below, Measuring voltage

it is normal 1) Insert T-adapter to
RTL.
Potentiometer
Between (1) and (3) 4.1 – 4.8 V
ON.
Between (2) and (3) 0.3 – 4.7 V
Measuring resistance
Switch 1) Turn ignition switch

Measure
Resistance OFF.
voltage, Pin (male) Lever position
Retarder lever RTL value 2) Disconnect RTL.
measure
resistance Released Max. 1 Ω
Between (4) position
and (6) Applied
position Min. 1 MΩ
Released Min. 1 MΩ
Between (5) position
and (6) Applied
position Max. 1 Ω

it is normal OFF.
2) Disconnect B03.
Brake cooling filter
B03 (male)
Measure Pin Retarder filter Resistance
value
clogging sensor resistance

Pin Brake oil Resistance
Foot brake oil pressure Measure pressure value
switch resistance Min. 1 MΩ
Between (1) (Max. 57 psi)

Pin Brake oil Resistance

Retarder oil pressure Measure pressure value
switch resistance Min. 1 MΩ
Between (1) (Max. 57 psi)
HM400-1L 20-15 1

Pin Parking brake Resistance
Parking brake oil Measure value
B17 (male)
pressure switch resistance
Between (1) When released Min. 1 MΩ
and (2) When applied Max. 1 Ω

Exhaust brake oil Measure Pin Exhaust brake Resistance

value
B30 (male)
Between (1) When released Min. 1 MΩ
and (2) When applied Max. 1 Ω

it is normal OFF.
Resistance 2) Disconnect B01.
Front brake (L.H.) wear Measure Pin Brake value
B01 (male)
switch resistance When normal Max. 1 Ω
Between (1)
and (2) When worn Min. 1 MΩ

it is normal OFF.

Front brake (R.H.) wear Measure Pin Brake value
B28 (male)
Between (1)

it is normal OFF.
Center brake (L.H.) Measure Pin Brake value
B02 (male)
wear switch resistance

it is normal OFF.
Center brake (R.H.) Measure Pin Brake value
B26 (male)
wear switch resistance

it is normal OFF.
Rear brake (L.H.) wear Measure Pin Brake value
B05 (male)
Between (1)

it is normal OFF.
Resistance
2) Disconnect B05.
Rear brake (R.H.) wear Measure Pin Brake value
B08 (male)
switch resistance
20-16 1 HM400-1L


it is normal HSL.
Dump lever Measure Between (4) and (1) 4.6 – 5.4 V
HSL ON.
(potentiometer) voltage Between (3) and (1) 0.3 – 4.7 V
Between (2) and (1) 0.3 – 4.7 V

it is normal B34.
Measure 2) Turn ignition switch
Body positioner sensor B34 (male) Between (3) and (1) 4.6 – 5.4 V
voltage ON.
Between (2) and (1) 0.3 – 4.7 V

it is normal OFF.
Front differential lock Measure
B35 (male) Between (1) and (2) 20 Ω 2) Disconnect B35.
solenoid resistance

it is normal OFF.
Rear differential lock Measure
solenoid resistance

it is normal OFF.
Front brake pressure Measure
reducing valve resistance

it is normal OFF.
Rear brake pressure Measure
reducing valve resistance

it is normal OFF.
Measure
Exhaust brake solenoid B29 (male) Between (1) and (2) 20 – 60 Ω 2) Disconnect B29.
resistance

it is normal OFF.
Dump lever (kick-out Measure
LKO (male) Between (1) and (2) 39Ω ± 5% 2) Disconnect LKO.
solenoid) resistance

it is normal
OFF.
Dump pilot valve Measure
B31 (male) 2) Disconnect B31.
(selector solenoid) resistance Between (1) and (2) Approx. 30 Ω

it is normal OFF.
Dump pilot valve (EPC Measure 2) Disconnect B32.
B32 (male) Between (1) and (2) Approx. 30 Ω
solenoid) resistance
HM400-1L 20-17 1

it is normal OFF.
Pin Switch Resistance 2) Disconnect CK1.
Machine monitor check Measure value
CK1 (male)
switch resistance Released Max. 1 Ω
Between (3)
and (6) Pressed Min. 1 MΩ

it is normal OFF.
Resistance 2) Disconnect CH1.
Pin Switch value
Machine mode selector Measure
CH1 (male) Between (2) [ ] Pressed Max. 1Ω
switch 1 resistance and (3) Neutral Min. 1 MΩ
Between (1) Neutral Min. 1 MΩ
and (3) [ ] Pressed Max. 1 Ω

it is normal OFF.
Resistance 2) Disconnect CH2.
Pin Switch value
Machine mode selector Measure [>] Pressed Max. 1 Ω
CH2 (male) Between (2)
switch 2 resistance and (3) Neutral Min. 1 MΩ
and (3) [<] Pressed Max. 1 Ω
Machine monitor system

it is normal OFF.
Resistance 2) Disconnect PWM.
Power mode selector PWM Measure Pin Switch value
switch (male) resistance
Between (1) Up Min. 1 MΩ
and (3) Down Max. 1 Ω

it is normal OFF.
Resistance 2) Disconnect AISS.
AISS Measure Pin Switch value
AISS LOW switch
(male) resistance

it is normal OFF.
Resistance 2) Disconnect DFL.
Pin Switch value
Left and right Measure Up Max. 1 Ω
DFL (male) Between (1)
differential lock switch resistance and (3) Neutral Min. 1 MΩ

it is normal OFF.
Resistance 2) Disconnect DFS.
Left and right Measure Pin Pedal value
DFS (male)
differential lock pedal resistance Released Min. 1 MΩ
Between (A)
and (B) Depressed Max. 1 Ω
20-18 1 HM400-1L

it is normal OFF.
Pin Switch Resistance 2) Disconnect DEF.
Inter-axle differential Measure value
DEF (male)
lock switch resistance Up Min. 1 MΩ
Between (1)

Machine monitor system

it is normal OFF.
2) Disconnect EXH.
Pin Switch Resistance
value
Measure
Exhaust brake switch EXH (male) Between (1) Up Max. 1 Ω
resistance and (2) Neutral Min. 1 MΩ

it is normal OFF.
Resistance 2) Disconnect SBS.
Measure Pin Belt value
Seat belt switch SBS (male)
resistance Removed Min. 1 MΩ
Between (1)
and (2) Fitted Max. 1 Ω

it is normal OFF.
Resistance 2) Disconnect WRF.
Working lamp (front) WRF Measure Pin Switch value

it is normal OFF.
Resistance 2) Disconnect WRR.
Working lamp (rear) WRR Measure Pin Switch value
Others (other than controllers)

it is normal OFF.
Resistance 2) Disconnect HAZ.
Measure Pin Switch value
Hazard lamp switch HAZ (male)
resistance

it is normal LS.
Night lighting dimmer Measure 2) Turn ignition switch
LS Between (1) and (3) 20 – 30 V
switch voltage ON.
Between (2) and (3) 6 – 27 V

it is normal OFF.
Resistance
2) Disconnect FOG.
Measure Pin Switch
Fog lamp switch FOG (male) value
resistance
HM400-1L 20-19 1

it is normal OFF.
Pin Switch Resistance 2) Disconnect BLS.
Yellow rotating lamp Measure value
BLS (male)
switch resistance Up Min. 1 MΩ
Between (1)

it is normal OFF.
Resistance 2) Disconnect SDE.
Measure Pin Switch value
Side lamp switch SDE (male)
resistance

it is normal OFF.
Position Switch Resistance 2) Disconnect ST1
Emergency steering ST Measure value
and ST2.
switch (terminal) resistance OFF Min. 1 MΩ
Between ST1
and ST2 ON Max. 1 Ω

it is normal OFF.
Measure Pin Switch Resistance 2) Disconnect R33.
Parking brake switch R33 (male) value

resistance

it is normal OFF.
Differential lock Resistance 2) Disconnect B21.
Pin oil pressure value
Front accumulator oil Measure
pressure switch resistance Min. 1 MΩ
Between (1) (Max. 50 711 psi)
Max. 1 Ω
(Min. 60 856 psi)

it is normal OFF.
Pin Differential lock Resistance 2) Disconnect B20.
oil pressure value
Rear accumulator oil Measure
B20 (male) Max. 4.9 MPa Min. 1 MΩ
Between (1) (Max. 50 711 psi)
(Min. 60 856 psi) Max. 1 Ω

it is normal OFF.
Measure Between (1) and (2) 30 – 50 Ω 2) Disconnect B14.
Parking brake solenoid B14 (male)
resistance
Between (1)(2) and Min. 1 MΩ
ground

it is normal OFF.
Between (1) and (2) 100 – 500 Ω 2) Disconnect relay
Measure
Relay (5-pin type) (male) connector.
resistance Between (5) and (5) Min. 1 MΩ
Between (3) and (6) Max. 1 Ω
20-20 1 HM400-1L


it is normal OFF.
Between (5) and (6) 100 – 500 Ω 2) Disconnect relay
Measure connector.
Relay (6-pin type) – (male)
resistance Between (1) and (2) Min. 1 MΩ
Between (3) and (4) Max. 1 Ω

it is normal OFF.
2) Disconnect CM.
Switch (1) (2) (3) ★ Between
Measure
Lamp switch CM (male) OFF connected pins:
resistance
Small Max. 1 Ω
Between other
Head
pins: Min. 1 MΩ
Combination switch

it is normal
Measure Switch (4) (5)
Dimmer switch CM (male)
resistance OFF
PASS

it is normal
Switch (6) (7) (8)
Turn signal Measure
CM (male) L (left)
switch resistance
N
R (right)

it is normal OFF.
2) Disconnect WPS.
Switch (1) (2) (3) (4) (5) (6)
★ Between
OFF connected pins:
Front wiper WPS Measure Max. 1 Ω
INT Between other
pins: Min. 1 MΩ
LOW
Wiper switchES
HIGH
WASH

it is normal
Switch (7) (8) (9) (10)
WASH
Rear wiper WPS Measure
OFF
ON
WASH
HM400-1L 20-21 1
TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
12
TOOLS FOR TESTING AND ADJUSTING
Measurement Item Symbol Part Number Part Name Remarks
-101 - -199.9kPa
Air supply pressure A 799-201-2202 Boost gauge kit
{-760 - 1,500mmHg}
Exhaust, coolant, and oil Digital temperature
B 799-101-1502 –99.9 – 1,299ºC
temperatures gauge
1 799-201-9000 Handy Smoke Checker Discoloration 0 - 70%
(with standard color)
Exhaust color C Commercially
2 Smoke meter (Discoloration % x 1/10 = Bosch
available index)
Commercially
Valve clearance D Feeler gauge Intake: 0.35 mm; exhaust: 0.57 mm
available
Blow-by pressure E 799-201-1504 Blow-by checker 0 – 4,9MPa {0 – 500 mmH2O}
2.5 , 5.9, 39.2 , 58.8 MPa

799-101-5002 Hydraulic tester
{25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester 58.8 MPa {600 kg/cm2}
799-401-2701 Hydraulic gauge 0.98 MPa {10 kg/cm2}

799-101-5220 Nipple
Oil pressure F M10 x P1.25
07002-11023 O-ring
799-101-5260 Nipple
M12 x P1.5
799-101-5270 Seal washer
799-101-5230 Nipple
M14 x P1.5
07002-11423 Seal washer
Brake oil pressure G 793-520-1805 Brake test kit
1 792-610-1000 Suspension tool H2 - H6: Pump assembly
Kit Part No.: 792-610-1100
2 792-610-1130 Pump
3 792-610-1110 Hose H7 - H13: Charging tool assembly
Kit Part No.: 792-610-1200
4 792-610-1120 Joint
5 07020-21732 Fitting
6 792-610-1140 Pump
Suspension cylinder H 7 792-610-1250 Valve

8 792-610-1260 Nipple
9 792-610-1480 Stem
10 792-610-1640 Joint
11 792-610-1400 Regulator
12 792-610-1430 Gauge 24.5MPa {250kg/cm2}
13 792-610-1440 Gauge 9.8MPa {100kg/cm2}

79A-264-0021 Push-pull scale 0 – 294 N {0 – 30 kg}
Operating effort H
79A-264-0091 Push-pull scale 0 – 490 N {0 – 50 kg}
20-22 1 HM400-1L
TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
Measurement Item Symbol Part Number Part Name Remarks
Commercially
Stroke, hydraulic drift J Scale
available
Commercially
Work equipment speed K Stop watch
available
Voltage, resistance L 79A-264-0211 Tester
790-601-8000 T-adapter kit
790-601-9000 T-adapter kit For HD30, DT connector
Wiring harnesses, sensors M
799-601-9420 Adapter For engine oil pressure sensor
799-601-9430 Socket For fuel supply pump PCV
HM400-1L 20-23 1
TESTING AND ADJUSTING ENGINE COMPONENTS
ENGINE COMPONENTS
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL for tools and
proper procedures.
MEASURING EXHAUST SMOKE
MEASURING EXHAUST TEMPERATURE
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING CRANCASE PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING BOOST PRESSURE
MEASURING FUEL PRESSURE
BLEEDING AIR FROM FUEL SYSTEM
20-24 1 HM400-1L
12
ADJUSTING ENGINE SPEED SENSOR
★ The G and Ne speed sensor for the engine controller cannot be adjusted.
★ Adjust the engine speed sensor (EREV) for the transmission controller as follows.
1. Tilt the cab up.

• For details, see TILTING THE CAB UP.
2. Install sensor (1) until it contacts the tip of the toothed flywheel
ring gear (2).
• Be careful not to let the tip of the sensor be scratched or to let
any iron particles stick to the sensor tip.
Thread: Hydraulic Sealant
3. When sensor (1) contacts gear (2), turn it back 1/2 - 2/3 turn. Adjust
clearance a between the tip of the sensor and the tip of the gear
tooth to 0.75 - 1.00 mm. (0.03 - 0.04 in)
4. Tighten sensor (1) with nut (3).
Locknut: 69 - 74 Nm (51 - 55 ft/lbs)
HM400-1L 20-25 1
ADJUSTING “V” BELT TENSION
Checking Tension
• Measure the deflection when the belt is pressed with a finger at a point (marked by the arrow) at the center of the belt
between the fan pulley and crankshaft pulley.
• Check each belt individually.
• Pushing force: 98 N (22 lbs)
• Deflection: 13 - 15 mm (1 - 1.2) new part
• 17 - 19 mm (2 - 2.1) when adjusting tension
Adjusting Belt
• If the deflection is not within the specified range, adjust as follows.
1. Install 2 belts (1).
2. Move tension pulley (3) with adjustment bolt (2) and adjust the tension of the belts.
3. After adjusting, check the belt tension again.
20-26 1 HM400-1L
ADJUSTING ALTERNATOR BELT
Checking Tension
• Measure the deflection when the belt is pressed with a finger at a point (marked by the arrow) midway between the
alternator pulley and drive pulley.
• Pushing force: 98 N (22 lbs)
• Deflection: 13 - 16 mm (1 - 1.2 in)
Adjusting Belt
1. Loosen 3 mounting bolts of alternator (1) and adjustment rod (2).
2. Loosen locknut (3), move alternator (1) with adjustment nut (4), and adjust the tension of the belt.
3. Tighten locknut (3).
4. Tighten 3 mounting bolts of alternator (1) and adjustment rod (2).
HM400-1L 20-27 1
12
ADJUSTING REFRIGERANT COMPRESSOR BELT
Checking Tension
• Measure the deflection when the belt is pressed with a finger at a point (marked by the arrow) midway between the
compressor pulley and crankshaft pulley.
• Pushing force: 58.8 Nm (13 lbs)
• Deflection: 10 mm (0.4 in)
Adjusting Belt
1. Loosen 3 mounting bolts of compressor assembly (1) and adjustment rod (2).
2. Loosen locknut (3), move compressor assembly (1) with adjustment nut (4), and adjust the tension of the belt.
4. Tighten 3 mounting bolts of compressor assembly (1) and adjustment rod (3).
20-28 1 HM400-1L
TESTING AND ADJUSTING TESTING TORQUE CONVERTER STALL SPEED
12
TESTING TORQUE CONVERTER STALL SPEED
WARNING! Stop the machine on flat level ground, turn the parking brake switch ON, and block the
tires.
1. Switch the machine monitor display to the monitoring function of

service mode 1 and display the following 2 items at the same time
with the monitoring function.
• Monitoring items
(1) Code No. 01001: Engine speed
(2) Code No. 30100:
• Torque converter oil temperature
For details of the method of operation, (See SPECIAL FUNCTIONS OF MACHINE MONITOR).
2. Start the engine and raise the temperature of the hydraulic oil and transmission oil.
• Transmission oil temperature: 60 - 80oC (140 - 176oF)
• Hydraulic oil temperature: 45 - 55oC (113 - 131oF)
3. Turn the parking brake switch ON, depress the parking brake pedal, then set the gearshift lever to the D position.
• If the gearshift lever is moved to any position other than the D position, the machine may move off even if the brake
is depressed, always measure in the D position.
4. Depress the accelerator pedal gradually, run the engine at high idling and stall the torque converter to raise the torque
converter oil temperature.
Remark
There is danger of damage to the internal parts of the transmission, so never operate the gearshift lever to any
position other than the D position during the stall operation.
5. When the torque converter oil temperature goes above 90oC (194oF), return the engine immediately to a low idle and
move the gearshift lever to the N position.
Remark
Never operate the gearshift lever with the accelerator pedal depressed. This will cause a sudden shock which may
lead to a reduction in the service life of the machine.
6. Run the engine at a mid-range speed, and when the torque converter oil temperature goes down to approximately 80oC
(176oF), run at low idling. (Keep the gearshift lever at the N position).
7. Repeat Steps 3 - 6 and equalize the oil temperature in the torque converter and transmission.
8. At the same time as repeating Steps 3 and 4, measure the stall speed when the torque converter oil temperature is 80oC
(176oF). Measure the stall speed 2 or 3 times.
• The stall speed may vary according to the following conditions, so always measure the stall speed at the time of delivery.
• Variations according to the engine serial number
• Variations in engine output due to atmospheric pressure and temperature
• Variations due to consumption torque of accessories
• Variations due to features of the torque converter
• Variations according to the method of measuring the stall
HM400-1L 20-29 1
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURES
12
MEASURING POWER TRAIN OIL PRESSURES
WARNING!
• Stop the machine on flat level ground, turn the parking brake switch ON, and block the tires.
• Wait for the oil temperature to go down fully before removing or installing the measuring tools.
• If measuring the oil pressure while traveling, make sure that there is a wide travel area and check
the safety conditions of the surrounding area.
• When tilting the cab up or down, See TILTING THE CAP UP for details
★ Table of oil pressure testing port locations
No. Pressure Test Location kg/cm2

(psi)
1 Transmission main relief 60 (853)
2 Torque converter inlet port 60 (853)
3 Torque converter outlet port 10 (142)(
4 Torque converter lock-up clutch 60 (853)
5 Transmission Lo clutch 60 (853)
6 Transmission Hi clutch 60 (853)
7 Transmission 1st clutch 60 (853)
8 Transmission 2nd clutch 60 (853)
9 Transmission 3rd clutch 60 (853)
10 Transmission R clutch 60 (853)
11 Inter-axle differential lock clutch 60 (853)
20-30 1 HM400-1L
MEASURING POWER TRAIN MAIN RELIEF PRESSURE

1. Tilt the cab up.
2. Remove oil pressure test plug (1), then install nipple and hose (1).
Pull the hose out to the rear of the transmission.
3. Lower the cab down to its original position.
4. Connect oil pressure gauge.
5. Start the engine and raise the temperature of the torque converter oil
to the operating range.
6. Keep the gearshift lever at the N position and measure the oil
pressure at low idling and high idling.
7. After completing the test, remove the test equipment and restore to original condition.
MEASURING TORQUE CONVERTER “INLET” OIL PRESSURE

1. Install hose (1) to oil pressure coupler (2).
pressure at high idle.
5. After completing the test, remove the test equipment and restore to
original condition.
MEASURING TORQUE CONVERTER “OUTLET” OIL PRESSURE

1. Tilt the cab up.
2. Remove oil pressure test plug (3), then install nipple and hose (1).
Pull the hose out to the rear of the transmission.
3. Lower the cab down to its original position.
pressure at high idling.
7. After completing the measurement, remove the measuring equipment and set to the original condition.
HM400-1L 20-31 1
12
MEASURING TORQUE CONVERTER “LOCK-UP” CLUTCH PRESSURE
Table Of Gearshift Lever Positions, Speed Ranges, And Clutches Actuated
Speed range
Gearshift lever Clutches
R2 R1 N D 5 4 3 2 1 Lo Hi 1st 2nd 3rd R

F1
F2
F3
F4
F5
F6
N
R1
R2
★ The mark indicates the speed ranges that are actuated for each position of the gearshift lever.
★ The mark and mark indicate the clutches that are actuated for each travel speed.
★ The mark indicates the speed range when measuring the oil pressure for each clutch.
1. Remove the ECMV cover.
2. Remove oil pressure test plug (4), then install nipple and hose (1)
and connect oil pressure gauge.
4. Turn the parking brake switch OFF, depress the parking brake
pedal, then set the gearshift lever to position 1.
5. Release the brake, travel at a high idle speed, and measure the oil
pressure when the lock-up pilot lamp lights up.
• In F1, a maximum travel speed of approximately 7 km/h
(5mph) is reached.
6. After completing the tests, remove the test equipment and return machine to the original condition.
20-32 1 HM400-1L
MEASURING TRANSMISSION “LO” CLUTCH PRESSURE

5. Release the brake and measure the oil pressure when traveling at
high idle.
• In F1, a maximum travel speed of approximately 7 km/h (5
m.p.h.).
6. After completing the tests, remove the test equipment and return machine to the original condition.
MEASURING TRANSMISSION “HI” CLUTCH PRESSURE

5. Release the brake, travel at high idling, and measure the oil
pressure when the shift indicator shows “2”.
mph).
MEASURING TRANSMISSION “1ST” CLUTCH PRESSURE

high idle.
HM400-1L 20-33 1
• In F1, a maximum travel speed of approximately 7 km/h (7 mph).
6. After completing the test, remove the testing equipment and return machine to the original condition.
MEASURING TRANSMISSION “2ND” CLUTCH PRESSURE

5. Release the brake, travel at high idle, and measure the oil pressure
when the shift indicator shows “3”.
mph).
MEASURING TRANSMISSION “3RD” CLUTCH PRESSURE

5. Release the brake, travel at high idle, and measure the oil pressure
when the shift indicator shows “5”.
mph).
20-34 1 HM400-1L
MEASURING TRANSMISSION “R” CLUTCH PRESSURE

pedal, then set the gearshift lever to position R1.
high idle.
• In R1, a maximum travel speed of approximately 7 km/h (4
mph).
MEASURING INTER-AXLE “DIFFERENTIAL LOCK” CLUTCH PRESSURE

4. Keep the gearshift lever in the N position and move the inter-axle
differential lock switch to the MANUAL position.
5. Measure the oil pressure when the engine is at high idle.
6. After completing the test, remove the testing equipment and return
machine to the original condition.
HM400-1L 20-35 1
TESTING AND ADJUSTING “L” AND “R” DIFFERENTIAL LOCK PRESSURE
12
“L” AND “R” DIFFERENTIAL LOCK PRESSURE
(Machine With Differential Lock)
WARNING!
• Stop the machine on flat level ground, turn the parking brake switch ON, and block the tires.
• Wait for the oil temperature to go down fully before removing or installing the measuring tools.
TESTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE

1. Tilt the cab up.
• For details, (See TILTING THE CAP UP).
2. Remove oil pressure pickup plug (1).
3. Install nipple and hose [1].
4. Lower the cab down and connect oil pressure gauge.

• When lowering the cab, be careful not to let test hose interfere
with the cab.
5. Run the engine and push in manual operation button (2) of the
differential lock solenoid valve and measure the oil pressure at high
idle.
• This type of testing requires two persons. One person shall
push in the manual operation button on the solenoid valve and
the other person shall operate the accelerator pedal and
measure the oil pressure in the operator's seat.
• The differential lock oil pressure is actuated while the manual
operation button is pushed IN, if the machine is stopped.
20-36 1 HM400-1L
12
TESTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE
1. Raise the dump body to it’s full height.
4. Lower the dump body and connect oil pressure gauge.
5. When lowering the dump body, be careful not to let test hose
interfere with the bed.
idle.
• The differential lock oil pressure is actuated while the manual operation button is pushed IN, if the machine is
stopped
7. After completing the test, remove the testing equipment and return the machine to the original condition.
TESTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE

1. Raise the dump body to it’s full height.
2. Remove oil pressure measurement plug (4).
HM400-1L 20-37 1
4. Lower the dump body and connect oil pressure gauge.
5. When lowering the dump body, be careful not to let test hose
interfere with the bed.
idle.
• The differential lock oil pressure is actuated while the manual
operation button is pushed IN, if the machine is stopped
7. After completing the measurement, remove the measuring

equipment and set to the original condition.
ADJUSTING FRONT AXLE DIFFERENTIAL LOCK OIL PRESSURE

• If the front axle differential lock oil pressure is not correct, adjust
relief valve (5) of the front axle differential lock valve as follows.
1. Remove cap (6). Loosen locknut (7).
2. Turn adjustment screw (8) and adjust the oil pressure.
3. Adjust with the adjustment screw as follows.

• To INCREASE pressure, turn clockwise
• To DECREASE pressure, turn counterclockwise
4. Hold adjustment screw (8) in position and tighten locknut (7).

Install cap (6).
5. After completing the adjustment, repeat the procedure for

measurement to check the oil pressure again.
20-38 1 HM400-1L
ADJUSTING CENTER AXLE DIFFERENTIAL LOCK OIL PRESSURE

• If the center axle differential lock oil pressure is not correct, adjust
relief valve (9) of the center axle differential lock valve as follows.
1. Remove cap (10).
2. Loosen locknut (11).
3. Turn adjustment screw (12) and adjust the oil pressure.

6. Install cap (10).
7. After completing the adjustment, repeat the procedure for measurement to check the oil pressure again.
ADJUSTING REAR AXLE DIFFERENTIAL LOCK OIL PRESSURE

If the rear axle differential lock oil pressure is not correct, adjust relief
valve (13) of the rear axle differential lock valve.
The procedure for adjusting is the same as for the center differential
lock valve.
HM400-1L 20-39 1
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
12
ADJUSTING TRANSMISSION SPEED SENSOR
★ There are 4 speed sensors installed to the transmission. Adjust each sensor as follows.
• N1: Input shaft speed sensor
• N2: Intermediate shaft speed sensor
• N3: Output shaft R speed sensor
• FE1: Output shaft F speed sensor
• For the input shaft speed sensor, tilt the cab up before carrying out adjustment.
• For the intermediate shaft speed sensor and output F shaft speed sensor, remove the transmission and front differential
assembly before carrying out adjustment.
20-40 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
1. Screw in until the tip of sensor (1) contacts the face or tip of the
tooth of gear (2). Before installing, check that the tip of the sensor
is not scratched and that there are no iron particles sticking to the
sensor tip.
Thread portion: Gasket sealant (LG-5)
2. Turn back sensor (3) 1/2 - 1 turn from this position. Adjust
clearance a between the tip of the sensor and the tip of the gear
tooth to approximately 1.5 mm (0.06 in)
3. Secure nut (7) with sensor (5).
Nut: 49.0 - 68.6 Nm (36 - 51 ft/lbs)
HM400-1L 20-41 1
TESTING AND ADJUSTING TESTING AND ADJUSTING BRAKE OIL PRESSURE
TESTING AND ADJUSTING BRAKE OIL PRESSURE
tires.
MEASURING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE

1. Measure the charge valve oil pressure at remote pressure detection
port (1).
2. Install hose [1] and connect oil pressure gauge.

• Use a 39.2 MPa {400 kg/cm2} (5,690 PSI) pressure gauge.
3. Start the engine.
4. Measure the cut-in pressure at high idle.
A. Repeatedly depress and release the brake pedal to gradually

lower the pressure inside the accumulator.
B. Measure the pressure at the point where the indicator of oil

pressure gauge stops going down and starts to go up again.
C. Measure the cut-out pressure at high idle.
D. Measure the oil pressure when the pressure goes up after the
cut in and the indicator of pressure gauge stops.
5. After completing the measurement, remove the testing equipment

and return machine to the original condition.
MEASURING WHEEL BRAKE ACTUATION AND PRESSURE DROP

★ Use the same procedure to measure the front brake circuit, center brake circuit, and rear brake circuit.
1. Remove air bleeder (2) of the slack adjuster.
20-42 1 HM400-1L
2. Install brake test kit G and bleed the air from the brake circuit.
• For details, (See BLEEDING AIR FROM BRAKE CIRCUIT).
3. Measure the actuation pressure of the foot brake under the

following conditions.
A. Run the engine for several minutes at low idling to charge the
accumulator, then stop the engine.
B. Depress the brake pedal fully and measure the oil pressure.
4. Measure the actuation pressure of the retarder brake under the

A. Run the engine for several minutes at low idling to charge the accumulator, then stop the engine.
B. Turn the ignition switch ON.
C. Pull the retarder lever fully back and measure the oil pressure.
5. Measure the drop in the pressure of the foot brake under the following conditions.
A. Check that the foot brake actuation pressure and the retarder actuation pressure are correct before starting.
B. Run the engine for several minutes at low idling to charge the accumulator, then stop the engine.
C. Depress the brake pedal fully and measure the oil pressure.
D. Keep the brake pedal depressed.
E. Measure the oil pressure after 5 minutes and calculate the drop in pressure.
• Bleed the air from the brake circuit.
• For details, See BLEEDING AIR FROM BRAKE CIRCUIT.
MEASURING ACTUATION PRESSURE ON PARKING BRAKE

1. Remove inlet port plug (3) of parking brake cylinder.
• Check to be sure the parking brake switch is ON before
carrying out the operation.
HM400-1L 20-43 1
2. Install nipple [1] and hose [2], and connect oil pressure gauge.
• Use a 39.2 MPa {400 kg/cm2} (5,690 PSI) pressure gauge.
3. Start the engine and operate the parking brake switch several times
at high idling to bleed the air from the circuit.
4. Stop the engine and turn the ignition switch ON.
5. Measure oil pressure when parking brake switch is turned OFF.

7. Check to be sure the parking brake switch is ON before carrying

out the operation.
MEASURING ACTUATION PRESSURE OF EXHAUST BRAKE SOLENOID

(Machine Equipped With Exhaust Brake)
1. Open the engine hood.
2. Disconnect hose (4) of the exhaust brake cylinder.
3. Install adapter [1] and nipple and hose [2], and connect oil pressure
gauge.
• Use a 5.9 MPa {60 kg/cm2} (854 psi) oil pressure gauge.
20-44 1 HM400-1L
4. Start the engine and set the exhaust brake switch to position (a).
5. Turn the parking brake OFF.
6. Drive the machine forward and measure the oil pressure when the
exhaust brake pilot lamp lights up.
• If the accelerator pedal is released while the machine is
traveling with exhaust brake switch at position (a) and the
torque converter in the lock-up condition, the exhaust brake is
actuated.

8. Check to be sure the parking brake switch is ON before carrying out the operation.
ADJUSTING CHARGE VALVE CUT-IN AND CUT-OUT PRESSURE

• If the cut-in pressure and cut-out pressure of the charge valve are
not correct, adjust the R1 relief valve of charge valve (5) as follows.
• If the R1 relief valve is adjusted, the cut-in pressure and cut-up
pressure will both change.
1. Remove mudguard sheet inside left front tire housing.
3. Turn adjustment screw (7) and adjust oil pressure.

Locknut: 10.2 Nm (90 in/lbs)
6. After completing the adjustment, repeat the procedure for measurement to check the oil pressure again.
HM400-1L 20-45 1
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
12
TESTING BRAKE PERFORMANCE
WARNING! Stop the machine on flat level ground and turn the parking brake switch ON.
TESTING BRAKING PERFORMANCE OF FOOT BRAKE

1. Start the engine and turn the parking brake switch OFF.
2. Fully depress the brake pedal, then set the gearshift lever to the D
position.
• Testing the performance of the foot brake must be carried out
with the gearshift lever at the D position. Do not place the
gearshift lever at any other position.
3. Depress the accelerator pedal gradually and check to be sure the

machine does not move when the torque converter is stalled at the specified speed.
4. After completing the inspection, run the engine at low idle and set the gearshift lever to the N position.
TESTING BRAKING PERFORMANCE OF RETARDER BRAKE

(Not Used In E-spec)
2. Pull the retarder lever fully back, then set the gearshift lever to the
D position.
• Testing of the performance of the retarder brake must be
carried out with the gearshift lever at the D position. Do not
place the gearshift lever at any other position.

machine does not move when the torque converter is stalled at the specified speed.
20-46 1 HM400-1L
TESTING AND ADJUSTING TESTING BRAKE PERFORMANCE
TESTING PARKING BRAKE BRAKING PERFORMANCE
WARNING! If the machine moves, it can cause serious injury or death. If the machine starts moving
during performance test, lower the engine speed immediately and set the gearshift lever
to the N position and depress the foot brake pedal.
1. Turn the parking brake switch ON and start the engine.
2. Place the gearshift lever at the D position.

• Testing of the performance of the foot brake must be carried
out with the gearshift lever at the D position. Do not place the
gearshift lever at any other position.

machine does not move when the torque converter is stalled at the
specified speed.
4. If the machine moves while the torque converter speed is below the specified speed, adjust the brake pad clearance,
referring to TESTING WEAR OF PARKING BRAKE PAD. Adjusting pad clearance.
TESTING OVERRUN PROTECTION BRAKING PERFORMANCE

(E-spec)
2. Insert a screwdriver in hole (a) on the side of the combination

switch box and move it to the lower end and place the gearshift
lever at the D position.
• Testing of the performance of the overrun protection brake
must be carried out with the gearshift lever at the D position.
Do not place the gearshift lever at any other position.
• If the screwdriver is inserted in hole (a) on the side of the
combination switch box and moved to the lower end, the
potentiometer in the switch box is rotated and the overrun
protection brake pilot lamp lights up.
3. Depress the accelerator pedal gradually and check that the machine
does not move when the torque converter is stalled at the specified
speed.
4. After completing the inspection, move the screwdriver inserted in

hole (a) to the upper end and remove it.
HM400-1L 20-47 1
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
12
BLEEDING AIR FROM BRAKE CIRCUIT
★ If the equipment in the brake circuit has been removed and installed again, bleed the air from the brake circuit as follows.
★ When bleeding the air from the wheel brake circuit, always bleed the air from the slack adjuster first, then bleed the air
from the wheel brake.
BLEEDING AIR FROM SLACK ADJUSTER PORTION OF WHEEL BRAKE

• Use the same procedure to measure the front brake circuit, center brake circuit, and rear brake circuit.
1. Connect air bleed hose [1] to air bleeder (1).
2. Start the engine and operate at low idling.
3. Bleed the air from the brake pedal circuit as follows.
A. Depress the brake pedal fully and hold it in position.
B. Loosen air bleeder (1) approximately 1/2 turn, then drain the
air mixed with the oil.
C. When no more air comes out with the oil, tighten air bleeder
(1).
Air bleeder: 10 - 20 Nm (89 - 177 in/lbs)
4. Bleed air from retarder brake circuit in the following procedure.

(Which is not used in E-SPEC)
A. Pull the retarder lever fully and hold it in position.
B. Loosen air bleeder (1) approximately 1/2 turn, then drain oil
mixed with oil.
C. When no more air comes out with the oil, tighten air bleeder
(1).
5. Bleed air from the overrun protection brake circuit in the following
procedure (E-SPEC).
A. Insert a screwdriver in hole (a) on the side of the combination

switch box and move it to the lower end and keep it in that
position.
B. Loosen air bleeder approximately 1/2 turn, then drain the air
mixed with the oil.
C. When no more air comes out with the oil, tighten air bleeder (1).
20-48 1 HM400-1L
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
6. After bleeding air, be sure to move the screwdriver inserted in hole (a) to the upper end and remove it.
7. After completing the adjustment, return machine to the original condition.
BLEEDING AIR FROM WHEEL BRAKE PORTION OF FOOT BRAKE CIRCUIT

• Use the same procedure to measure the front brake circuit, center brake circuit, and rear brake circuit.
1. Connect air bleed hose [1] to air bleeder (1).
3. Bleed the air from the brake pedal circuit as follows.
A. Depress the brake pedal fully and hold it in position.
B. Loosen air bleeder (1) approximately 1/2 turn, then drain the
air mixed with the oil.
4. When no more air comes out with the oil, tighten air bleeder (1).
BLEEDING AIR FROM PARKING BRAKE CIRCUIT

2. Use the parking brake switch to actuate and cancel the circuit several times.
• This operation automatically bleeds the air.
HM400-1L 20-49 1
TESTING AND ADJUSTING CHECKING WEAR LIMIT ON WHEEL BRAKE DISC
12
CHECKING WEAR LIMIT ON WHEEL BRAKE DISC
tires.
CHECKING BRAKE DISC
★ Carry out the inspection when the brake oil temperature is less than 60oC (140oF).
★ When the disk comes close to the wear limit, carry out the inspection more frequently. Be sure to carry out inspection of
the retarder braking performance at the same time.
1. Check to be sure the brakes other than parking brake are not being actuated.
2. Turn the ignition switch ON and check to be sure the retarder oil pressure caution lamp is not lighted up.
• If the lamp is lighted, the oil pressure in the brake circuit has dropped, start the engine and run it at approximately
2000 rpm. When the lamp goes out, stop the engine.
3. Remove cap nut (1) of the gauge.
4. Fully depress the brake pedal and hold it in position.

• When the engine is started, the brake cooling oil is actuated
and the inspection cannot be carried out accurately, always stop
the engine before carrying out inspection.
5. Push in the rod (2) of the gauge until it contacts the piston and
judge the amount of wear.
• There are three lines (A, B, C) on the rod. For the HM400-1L,
use line A.
• With a new machine, adjust so that initial mark a on the rod (2)
is aligned with the end face of guide (3).
• The adjustment position will move out of alignment, so do not
loosen the locknut on guide (3) except when replacing the disc.
• Limit mark b indicates the wear limit for the disc. If limit mark
b reaches the end face of guide (3), the disc has reached the
wear limit.
6. Install cap nut (1) of the gauge.
Cap nut: 14.7 - 19.6 Nm (130 - 173 in/lbs)
20-50 1 HM400-1L
12
CHECKING BRAKE PAD
tires. Before carrying out the inspection, start the engine and raise the dump body fully.
Then insert the lock pin and stop the engine
1. Remove top cover of parking brake.
2. Turn adjustment nut (1) counterclockwise to release the parking

brake.
3. Remove left and right brackets (2), then remove 2 each of spring (3)
and (4).
4. Remove 2 pads (5).
5. Measure thickness a of pad (5).

• Thickness limit of pad: 1.5 mm (0.06 in)
6. If either the front or rear pad has reached the thickness limit,
replace both pads at the same time.
HM400-1L 20-51 1
ADJUSTING PAD CLEARANCE

• If the pad wear has been inspected or the pad has been replaced with a new part, adjust the clearance as follows.
1. Install 2 pads (5).
2. Install 2 each of springs (4) and (3) to left and right brackets (2), then install left and right brackets (2).
3. There are two types of springs, so check the color, and be careful not to mistake the mounting position.
• Spring (4): Yellow
• Spring (3): Black
4. Screw 2 or 3 mounting bolts into the bracket and tighten temporarily.
5. Turn adjustment nut (1) clockwise until pad (5) is brought into tight contact with disc (6).
6. Measure clearances b and c between pad (5) and disc (6) and turn
adjustment nut (1) counterclockwise to loosen it until the clearance
is the specified amount.
• Standard clearance (total of b and c): 1.5 mm (0.06 in)
8. Repeatedly actuate and cancel with the parking brake switch to

adjust the pad clearance.
• When the parking brake is actuated in the direction of release,
adjustment nut (1) will turn clockwise, so repeat this operation
until it does not turn anymore.
9. Release the parking brake and check the clearance of the pad again.
• Clearance (total of b and c): 1.5 mm (0.06 in)
• If the clearance is not correct, carry out the adjustment again
from Step 3).
10. Tighten the mounting bolts of left and right brackets (2).
• Be careful not to let the mounting position move out of
alignment.
11. Check the clearance between pad (5) and disc (6) again.
• Target clearance (b + c on one side): Min. 0.5 mm (0.02 in)
• If the clearance on one side is narrow, move the mounting position of the left and right brackets to adjust.
20-52 1 HM400-1L
TESTING AND ADJUSTING RELEASING EMERGENCY PARKING BRAKE
12
RELEASING EMERGENCY PARKING BRAKE
★ If any problem occurs in the electrical system or hydraulic system of the parking brake and the parking brake is not
releasing, it is possible to release the brake temporarily as follows.
★ If any problem occurs in the hydraulic system, there is a strong possibility that the wheel brake will not work properly,
after releasing the parking brake, always tow the machine at low speed to a safe place.
★ When carrying out the operation to release the parking brake, stop the machine on flat level ground and check the
surrounding area before starting the operation. If the parking brake must be released on a slope in an emergency or other
unavoidable situation, put blocks securely under the tires.
1. Turn adjustment screw (1) on the parking brake slack adjuster

counterclockwise to create a gap between the pad and disc.
2. Tow the machine and move it to a safe place.

• After moving the machine, place blocks securely under the
tires.
HM400-1L 20-53 1
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
12
STEERING CIRCUIT PRESSURE
tires
MEASURING STEERING RELIEF OIL PRESSURE

1. Measure the steering relief pressure at remote pressure detection
port (1).
2. Install hose [1] and connect oil pressure gauge.

• Use a 39.2 MPa (5,685 psi) oil pressure gauge.
3. Start engine and operate the steering to one side (either left or
right).
4. Measure the oil pressure when the steering is relieved with the
engine at high idle.
20-54 1 HM400-1L
TESTING AND ADJUSTING STEERING CIRCUIT PRESSURE
12
ADJUSTING STEERING RELIEF OIL PRESSURE
• If the steering relief oil pressure is not correct, adjust relief valve
(2) on the flow amp valve as follows.
1. Remove plug (3), then remove locknut (4).
2. Turn adjustment screw (5) and adjust oil pressure.

4. Install locknut (4) and install plug (3).
5. After completing the adjustment, repeat the procedure for testing to

check the oil pressure again.
HM400-1L 20-55 1
TESTING AND ADJUSTING TESTING AND ADJUSTING SUSPENSION CYLINDER
12
TESTING AND ADJUSTING SUSPENSION CYLINDER
WARNING! Stop the machine on flat ground, turn the parking brake switch ON, and block the tires.
CHECKING CYLINDER LENGTH

• Test the installed length of the suspension cylinder under the
• Machine standing on horizontal road surface
• Engine stopped
• Dump body unloaded
• Installed length a of front cylinder: 168 ± 10 mm (6.6 ± 0.5 in)
• Installed length b of front cylinder: 111 ± 5 mm (4.4 ± 0.2 in)
• If the length of the cylinder is not correct, use the procedure in
Steps 2 to 5 to adjust.
RELEASING NITROGEN GAS

1. Set a hydraulic jack firmly under the frame of the machine and raise
the tires slightly from the ground.
• Use a 50 ton jack.
• When carrying out work at the front, jack up the front frame
until the front tires come slightly off the ground.
• When carrying out work at the rear, jack up the frame until
either the 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.
• If oil spurts out from the valve together with the nitrogen gas,
tighten the valve slightly until no more oil comes outs and take time to release the nitrogen gas slowly.
4. Operate the hydraulic jack to lower the frame slowly until the suspension cylinder is retracted to the specified oil volume
length.
• Use the hydraulic jack carefully to prevent the suspension cylinder from being retracted too far and suffering damage.
• Specified front oil volume length: 68 ± 3 mm (3.0 ± 0.1 in)
• Specified rear oil volume length: 81 ± 3 mm (3.2 ± 0.1 in)
20-56 1 HM400-1L
12
ADJUSTING OIL LEVEL
• Adjust the oil level after completing the release of the nitrogen gas.
1. Check to be sure the suspension cylinder is the specified oil volume

length.
• Specified front oil volume length: 68 ± 3 mm (3.0 ± 0.1 in)
• Specified rear oil volume length: 81 ± 3 mm (3.2 ± 0.1 in)
2. Operate the hydraulic jack carefully.
3. Remove oil level valve (2).
4. Remove the valve body from air supply valve (3), then install joint
H6.
5. Install fitting H5 to joint H4, then connect hose H3 and pump H2.
6. Operate pump H2 to release the gas from the mounting port of oil
level valve (2).
7. Pump the oil out from the mounting port until no more bubbles
come out with the oil, then fill with oil.
• Front cylinder oil charge amount (reference): 6.0
• Rear cylinder oil charge amount (reference): 6.0 l
8. Install oil level valve (2).
Oil level valve: 39.2 - 49.0 Nm (347 -434 in/lbs)
9. Remove suspension tools H2 - H5, then remove air supply valve (3).
Air supply valve: 39.2 - 49.0 Nm (434 in/lbs)
HM400-1L 20-57 1
12
CHARGING WITH NITROGEN GAS
• Charge with nitrogen gas after completing the adjustment of the oil
level.
1. Remove the cap at the top of air supply valve (3).
2. Connect suspension tools H7 - H12 as shown in the diagram.

• Connect joint H10 to the air supply valve.
• Before installing the regulator, blow the filter at the
mouthpiece thoroughly with nitrogen gas minimum. 0.98 MPa
(142 psi)) to prevent the entry of dirt or dust.
3. Open the valve of nitrogen gas cylinder (1) and check the pressure
(internal pressure of the cylinder) indicated by gauge H12.
• The indicated pressure must not be higher than the internal
pressure of the cylinder 0.98 MPa (142 psi).
• Internal pressure of cylinder (both front and rear): 4.03 MPa
(624 psi).
4. Turn the handle of regulator H11 gradually to the left and set the
indicated pressure of gauge H13.
• Never charge the cylinder with nitrogen gas at a pressure of
more than 3.9 MPa (566 psi) and extend the cylinder fully.
5. Operate the handle of joint H10 and valve H7 and the suspension
cylinder with nitrogen gas.
• Pump nitrogen gas into the left and right cylinders at the same time.
6. When the length of the left and right cylinders reaches the specified installation length, turn the handle of regulator H11 to
the left to stop charging with nitrogen gas.
7. Return the handle of joint H10 fully, loosen the air bleed plug of valve H7, and discharge the gas inside the hose.
8. Remove suspension tools H7 - H12.

• Be careful not to lose the O-ring of the air supply valve.
9. Install the cap at the top of air supply valve (3).
10. Install the cover of the suspension cylinder.
20-58 1 HM400-1L
12
ADJUSTING CYLINDER LENGTH
• Adjust the cylinder length after completion of charging with
nitrogen gas.
• When adjusting the cylinder length, stop the machine on a
horizontal surface with the dump body unloaded.
1. Drive the machine approximately 15 m (50 ft) forward, then stop

suddenly. Next, drive in reverse and stop the machine suddenly at
the original point. Repeat this procedure 3 or 4 times. Finally, apply
the retarder brake a little at a time and stop slowly.
• When using the retarder brake, stop as slowly as possible to
remove any sliding resistance in the cylinder (packing,
catching of the bushing).
2. Measure the installed length of the cylinder.

3. If the installed length is too long, adjust by discharging nitrogen gas from oil level valve (2).
• Loosen the oil level valve slightly and discharge a small amount of gas (not enough to make the cylinder move).
• If too much gas is discharged and the cylinder moves, the installed length may become shorter than the specified
installed length.
4. After completing the adjustment, repeat Steps 1) - 2) above and check the cylinder length again.
5. Check for any leakage of gas from oil level valve (2), air supply valve (3), and the cylinder gland.
• Use soapy water to check for leakage of gas.
Checking After Changing Oil Or Gas
1. If the machine is operated after changing the oil and gas, the gas will dissolve in the oil and saturate the oil inside the
cylinder. If this happens, the volume of the gas will decrease and the length of the cylinder will go below the permissible
value.
2. For this reason, check the installed length of the cylinder again 48 hours after changing the oil and the gas, and adjust the
gas if it is below the specified dimension.
Checking Cylinder Length According To Change In Ambient Temperature
1. The gas in the suspension will expand or contract according to the change in the ambient temperature when the machine is
working, so the length of the cylinder will change.
2. For this reason, in areas where there is a big difference in temperature during the year, carry out daily inspection and
adjust so that the installed length of the cylinder is within the specified range.
HM400-1L 20-59 1
TESTING AND ADJUSTING TILTING THE CAB UP
12
TILTING THE CAB UP
★ When carrying out inspection and maintenance 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 follows.
★ There are the following two methods of tilting the cab up, so select the method to match the operating conditions.
★ Method using built-in tilt-up cylinder
★ Method using external crane
★ When carrying out the operation with the built-in tilt-up cylinder, an external pump is needed, so prepare a pump.
PREPARATORY WORK
• To prevent interference between the cab and dump body, set the
steering facing directly to the front.
• Turn the parking brake switch ON and block the tires.
1. Open the engine hood.
2. Remove lock bar (1) from the storage place.
3. Remove 4 mounting bolts (2) each from the left and right mounts at
the front of the cab.
TILTING CAB UP
★ Using built-in cylinder
1. Move pin (1) of the rear mount of the cab from hole (2) to hole (4).
2. Disconnect cylinder hose (3), then connect the hydraulic pump to

the hose.
3. Operate the hydraulic pump and tilt the cab up.
4. Operate the pump within the specified pressure.

• Specified pressure for pump: 20.6 - 34.3 MPa (2,988 - 4,975
psi)
20-60 1 HM400-1L
TESTING AND ADJUSTING TILTING THE CAB UP
12
USING EXTERNAL CRANE
1. Install the lifting tool [1] to the top of the cab.
2. Raise the cab to tilt it up.
HOLDING CAB IN POSITION

1. Set lock bar (1) at the front left of the cab, then lower the cab slowly
and fix it in position.
• When the cab is tilted up with the built-in cylinder, release the
hydraulic pressure gradually, and lower the cab slowly.
2. Remove the external pump or external crane.

• Check that the cab is held securely in position by the lock bar.
LOWERING CAB DOWN

• Lower the cab down in the reverse order from tilting the cab up.
• After tilting the cab down, tighten the mounting bolts and return the lock bar to the storage place.
HM400-1L 20-61 1
TESTING AND ADJUSTING TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
12
TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
WARNING! Stop the machine on flat ground, turn the parking brake switch ON, and block the tires.
TESTING DUMP MAIN RELIEF OIL PRESSURE

1. The dump main circuit uses both the steering circuit and hydraulic
pump (basic pressure). The steering is a priority circuit structure, so
check that the steering circuit pressure is correct before measuring.
2. Measure the dump main relief oil pressure at remote pressure

detection port (1).
3. Install hose [1] and connect oil pressure gauge

• Use a 39.2 MPa (4975 psi) oil pressure gauge.
4. Start the engine and operate the dump body fully to LOWER and
RAISE.
5. Run at high idling, operate the dump lever, and measure the oil
pressure when there is RAISE relief or LOWER relief.
6. After completing the measurement, remove the measurement

ADJUSTING DUMP MAIN RELIEF OIL PRESSURE

• If the dump main relief oil pressure is abnormal, adjust it with relief
valve (1) of the hoist valve according to the following procedure.
1.Loosen locknut (2) and rotate adjustment screw (3).

• If the adjustment screw is;
• rotated to the right, the oil pressure is heightened.
• rotated to the left, the oil pressure is lowered.
★ If the adjustment screw is rotated 1 turn, the pressure is heightened
or lowered by 19.6 MPa (2,843 psi).
2. Support adjustment screw (3) with a screwdriver and tighten

locknut (2).
Tightening torque for locknut: 29 - 39 Nm (257 - 345 in/lbs)
3. After completing the adjustment, check the oil pressure again according to the procedure for measurement.
20-62 1 HM400-1L
TESTING AND ADJUSTING TESTING AND ADJUSTING DUMP CIRCUIT PRESSURE
MEASURING DUMP PILOT RELIEF OIL PRESSURE

1. Remove the side cover of the hydraulic tank.
3. Install a nipple and hose [1] and connect oil pressure gauge.
• Use a 5.9 MPa (856 psi) oil pressure gauge.
4. Run the engine at high idling and measure the oil pressure.
(Set the dump lever in neutral.)
5. After completing the measurement, remove the measurement

ADJUSTING DUMP PILOT RELIEF OIL PRESSURE

• If the dump pilot relief oil pressure is abnormal, adjust it with relief
valve (1) according to the following procedure.
1. Remove the cap and loosen locknut (2) and rotate adjustment screw
(3).
2.If the adjustment screw is

• rotated to the right, the oil pressure is heightened.
• rotated to the left, the oil pressure is lowered.
★ If the adjustment screw is rotated 1 turn, the pressure is heightened
or lowered by 1.8 MPa (261 psi).
3. Hold adjustment screw (3) and tighten locknut (2).
Tightening torque for locknut: 40 Nm (354 in/lbs)
4. After completing the adjustment, check the oil pressure again according to the procedure for measurement.
HM400-1L 20-63 1
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
12
ADJUSTING BODY POSITIONER SENSOR
★ If the body positioner rod has been disconnected and connected again or the body positioner sensor has been removed and
installed again, inspect and adjust the body positioner sensor as follows.
CHECKING SENSOR OUTPUT/INPUT VOLTAGE

1. Switch the machine monitor display to the monitoring function of
service mode 1 and display the body positioner sensor input
voltage.
• Monitoring item
• Code No. 34400: BODY POSITION
• For details of the method of operation, See SPECIAL
FUNCTIONS OF MACHINE MONITOR.
3. Operate the dump lever and check the monitoring voltage when the dump lever is operated fully to the LOWER position
and RAISE position.
• When operated fully to LOWER: 0.38 - 0.44 V
• When operated fully to RAISE: 4.00 - 4.70 V
ADJUSTING LINK LENGTH

• If the monitoring voltage is not within the normal range, adjust the length of the link as follows.
2. Remove mounting bolt (2).
3. Turn rod end (3) to adjust the length of the link.
4. Adjust the input voltage as follows.

• INCREASE link length to DECREASE voltage
• DECREASE link length to INCREASE voltage
5. Change in voltage for 1 turn of rod end: Approximately 0.04 V
6. Install mounting bolt (2).
8. Repeat the checking procedure above to check that the input voltage is within the normal range.
20-64 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING BODY POSITIONER SENSOR
12
CALIBRATING SYSTEM
1. Start the engine and raise the hydraulic oil temperature to 80 - 90 °C.
2. Lower the dump body fully and continue the LOWER relief at this position for at least 5 seconds.
3. Check that the dump body pilot lamp is not lighted up.
4. Run the engine at low idling and operate the dump body to the RAISE and FLOAT positions 10 times.
5. Operate to the end of the stroke for both the RAISE and FLOAT operations.
6. Run the engine at high idling and operate the dump body to RAISE and LOWER 10 times.
7. Operate to the end of the stroke for both the RAISE and LOWER operations.
HM400-1L 20-65 1
TESTING AND ADJUSTING ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT
12
ENGINE CONTROLLER HIGH-VOLTAGE CIRCUIT
★ The engine controller uses a high-voltage circuit (110 - 130 V) for the fuel injector drive. For this reason, the high-voltage
circuit is connected to the wiring harness and connectors from the engine controller to the fuel injector. Normally, high
voltage is output from the engine controller to the fuel injector only when the engine is running. When the engine stops,
the output also stops. If you touch the high-voltage circuit directly, there is danger of electrocution, so when carrying out
inspection, always obey the following precautions.
• The connectors included in the high-voltage circuit are as follows.

• Engine controller connectors: CN6, CN7
• Relay connectors: EG4, CJAA
• Injector connectors: CN1, CN2, CN3, CN4, CN5, CN6
• Terminals at injector ahead (inside the head cover)
1. Always turn the ignition switch OFF before disconnecting or

connecting the connectors.
2. Never start the engine if a T-adapter has been inserted or connected to the connector.
3. Operate the ignition switch only to the OFF or ON positions. Never turn it to the START position.
20-66 1 HM400-1L
TESTING AND ADJUSTING ADJUSTING TRANSMISSION CONTROLLER
12
ADJUSTING TRANSMISSION CONTROLLER
SETTING ROTARY SWITCH

• If the transmission controller has been replaced, set the rotary
switches for the network data and model selection as follows.
• Use a precision cross-head screwdriver and turn the rotary switch
slowly.
• The mark on the rotary switch is the guideline for setting.
1. Remove 2 grommets at the top of the controller.
2. Align the SW1 rotary switch and SW2 rotary switch with the set
position.
3. Rotary switches and set position
Switch Purpose of switch Position
SW1 Network data 0
SW2 Model data 0
ADJUSTING TRANSMISSION
• After carrying out any of the following operations, adjust the transmission in order to adjust the fitting between the
transmission and the transmission controller.
A. When the transmission has been overhauled or replaced
B. When the transmission control valve has been repaired or replaced
C. When the transmission controller has been replaced
D. When the power train speed sensor has been repaired or replaced
E. When the transmission oil temperature sensor has been repaired or replaced
F. When the transmission oil filter has become clogged and has been cleaned
G. When adjusting the transmission, use the service function of the machine monitor.
• For details of the method of operation, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
HM400-1L 20-67 1
TESTING AND ADJUSTING ESCAPE METHOD FOR ELECTRICAL SYSTEM
12
ESCAPE METHOD FOR ELECTRICAL SYSTEM
If any problem occurs in the electrical system on the engine or transmission control system, it may become impossible to start
the engine or to move the machine to a safe place, then carry out troubleshooting.
★ When problem occurs in engine control system and engine cannot be started
• Decide the escape method according to the following flowchart.
• For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
20-68 1 HM400-1L
★ When problem occurs in transmission control system and machine cannot be started
• Check the service code and determine the escape method from the following chart.
• For details of the method of checking the service code, see SPECIAL FUNCTIONS OF MACHINE MONITOR.
Condition when Lever position for speed range to move
Service code Escape method Remarks
failure occurred off after escape operation
1380MW Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 Occurrence condition 1:
1500L0 Occurrence condition 2 Escape procedure 2 - Speed range remains fixed;
when the machine is moved
15G0MW Occurrence condition 2 Escape procedure 3 D - 1: F2 off again, speed range does
15H0MW Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1 not shift
15J0MW Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 ´ When lever is returned to N,
transmission shifts to
15K0MW Occurrence condition 2 Escape procedure 3 D - 1: F3, R1 - R2: R1 neutral
15L0MW Occurrence condition 2 Escape procedure 3 D - 1: F2, R1 - R2: R1 Occurrence condition 2:
15M0MW Occurrence condition 2 Escape procedure 3 D - 1: F2, R1 - R2: R1 Transmission suddenly shifts
to neutral when the machine
15SBL1 Occurrence condition 3 Escape procedure 1 R1 - R2: R1 is traveling; after machine is
15SBMA Occurrence condition 3 Escape procedure 1 D - 1: F2 stopped, transmission stays in
15SCL1 Occurrence condition 3 Escape procedure 1 D - 1: F2 neutral even when lever is
operated, and machine does
15SCMA Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1 not move off
15SDL1 Occurrence condition 3 Escape procedure 1 D - 1: F1 Occurrence condition 3:
15SDMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 Transmission suddenly shifts
to neutral
15SEL1 Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 Occurrence condition 4:
15SEMA Occurrence condition 3 Escape procedure 1 D - 1: F3, R1 - R2: R2 After engine is started,
15SFL1 Occurrence condition 3 Escape procedure 1 D - 1: F3, R1 - R2: R2 transmission stays in neutral
even when lever is operated,
15SFMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 and machine does not move
15SGL1 Occurrence condition 3 Escape procedure 1 D - 1: F5, R1 - R2: R3 or equivalent off
15SGMA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 Occurrence condition 5:
Response of lever becomes
15SJL1 Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 abnormal; lever does not work
15SJMA Occurrence condition 2 Escape procedure 1 D - 1: F2, R1 - R2: R1 as operated
Normal travel possible if display returns When lever is operated,
D1B0KZ Occurrence condition 2 Escape procedure 4 transmission shifts to neutral
to normal (Note 1)
Occurrence condition 6:
Normal travel possible if display returns Speed range remains fixed;
DAQ0KK Occurrence condition 2 Escape procedure 5
to normal (Note 1) when the machine is moved
Normal travel possible if display returns off again, speed range does
DAQ2KK Occurrence condition 2 Escape procedure 4
to normal (Note 1) not shift
Normal travel possible if display returns ´ When lever is returned to N,
DAQ3KK Occurrence condition 4 Escape procedure 6 transmission shifts to
to normal (Note 1)
neutral, but after that,
Normal travel possible if display returns transmission does not shift
DAQ9KM Occurrence condition 4 Escape procedure 7
to normal (Note 1) to any speed range
Normal travel possible if display returns Note 1:
DAQ9KQ Occurrence condition 4 Escape procedure 7
to normal (Note 1) Even when the machine
Normal travel possible if display returns condition is restored after a
DAQAKQ Occurrence condition 1 Escape procedure 7 failure, the neutral condition is
to normal (Note 1)
maintained until the lever is
DDTGKA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 returned to the N position.
DDTHKA Occurrence condition 1 Escape procedure 1 D - 1: F2 Note 2:
DDTJKA Occurrence condition 1 Escape procedure 1 D - 1: F1 This phenomenon applies
when there is no display on
DDTKKA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 the machine monitor and
DDTLKA Occurrence condition 1 Escape procedure 1 D - 1: F3, R1 - R2: R2 there is also no display in the
DDTMKA Occurrence condition 1 Escape procedure 1 D - 1: F5, R1 - R2: R3 or equivalent display window of the
transmission controller.
DDTNKA Occurrence condition 1 Escape procedure 1 R1 - R2: R1
Normal travel possible if display returns
DF10KA Occurrence condition 5 Escape procedure 8
to normal (Note 1)
DF10KB Occurrence condition 2 Escape procedure 8
to normal (Note 1)
DLE2KA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
DLE2LC Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
DLF1KA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
DLF1LC Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1
HM400-1L 20-69 1
Condition when Lever position for speed range to move

Service code Escape method Remarks
failure occurred off after escape operation
DLF2KA Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 Note 1:
DLF2LC Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 Even when the machine
condition is restored after a
DLT3KA Occurrence condition 6 Escape procedure 3 D - 1: F2, R1 - R2: R1 failure, the neutral condition is
DLT3LC Occurrence condition 6 Escape procedure 3 D - 1: F2, R1 - R2: R1 maintained until the lever is
DXH1KB Occurrence condition 1 Escape procedure 1 D - 1: F2, R1 - R2: R1 returned to the N position.
Note 2:
DXH2KA Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1 This phenomenon applies
DXH2KB Occurrence condition 3 Escape procedure 1 D - 1: F1 when there is no display on
DXH3KA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 the machine monitor and
there is also no display in the
DXH3KB Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1 display window of the
DXH4KA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R2 transmission controller.
DXH4KB Occurrence condition 3 Escape procedure 1 D - 1: F3, R1 - R2: R2
DXH5KA Occurrence condition 3 Escape procedure 1 D - 1: F1, R1 - R2: R1
DXH6KA Occurrence condition 3 Escape procedure 1 D - 1: F2, R1 - R2: R1
DXH7KA Occurrence condition 3 Escape procedure 1 D - 1: F2
DXH7KB Occurrence condition 3 Escape procedure 1 D - 1: F1
- (Note 2) Occurrence condition 2 Escape procedure 5
to normal (Note 1)
★ Escape Procedure 1:
A. Stop traveling and return the gearshift lever to the N position.
B. Operate the gearshift lever again and move the machine off.
• When operating the gearshift lever, release the accelerator pedal.
• N → D or N → R1 - R2
A. Tow the machine.

• If the engine cannot be started and the machine is towed, the parking brake cannot be released by operating the
switch, so carry out the operation to release it temporarily. For details, See METHOD FOR EMERGENCY
RELEASE OF PARKING BRAKE.
A. Stop traveling and return the gearshift lever to the N position.
B. Connect and disconnect emergency escape connectors A1 (female) and A2 (male), and switch to the emergency
escape mode.
• Connectors A1 and A2 are installed to the front of the transmission controller.
• Connect and disconnect the connectors with the ignition switch at ON or with the engine started.
C. Operate the gearshift lever again and move the machine off.
• When operating the gearshift lever, release the accelerator pedal.
• N → D or N → R1 - R2
• The emergency escape mode is maintained until the ignition switch is turned OFF.
20-70 1 HM400-1L
12
A. Replace the transmission cut relay.

• Transmission cut relay: R15
A. Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
• Circuit breaker: No. 63 (80A)
• Fuse: BT3-No. 14 (10A)
A. Check the fuse unit and fuse, and if they are normal, replace the transmission controller.
• Fuse unit: Inside battery housing (30A)
• Fuse: BT2-No. 22 (10A)
• Check the model selection setting, and if it is normal, replace the transmission controller.
• For details of checking the model selection setting, See ADJUSTING TRANSMISSION CONTROLLER.
• Check the fuse, and if it is normal, replace the gearshift lever.
• Fuse: BT3-No. 10 (10A)
HM400-1L 20-71 1
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
12
ADJUSTING MACHINE MONITOR
Machine monitor rotary switches (SW1, SW2, SW3), dip switches (SW5, SW6), and option setting connectors (OP1 - OP7)
20-72 1 HM400-1L
• In the following cases, check the settings of the rotary switches, dip switches, and option setting connectors at the rear
face of the machine monitor, and change the settings as necessary.
• When the machine monitor has been removed and installed again
• When the tire size has been changed (travel speed compensation setting)
• When the exhaust brake has been installed or removed (exhaust brake setting)
• When the left and right differential lock has been installed or removed (left and right differential lock setting)
• When parts have been replaced with new parts (service meter, odometer, reverse travel odometer setting)
• When carrying out of these settings, it is necessary to use the special operation of the character display and mode
switch, so see SPECIAL FUNCTIONS OF MACHINE MONITOR.
• When service code [DAFOKM] is displayed
• There is probably mistaken connection of the option setting connector, so See TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM (MON MODE) for details.
Condition Of Switch Setting Functions And Option Setting Connectors
Switch Position Purpose of switch Connector Remarks
For standard tires, set to

SW1 0-F Travel speed compensation Not needed position 7
SW2 0-F Not used (always set to 0) OP3 always released
SW3 0-F Not used (always set to 0) Not needed
OFF Odometer display unit: km

Set to ON only in areas where
1 Not needed mile display is used
ON Odometer display unit: Mile
OFF Exhaust brake: Not installed Released

2 OP1
ON Exhaust brake: Installed Connected
SW5
OFF
3 Not used (always set to 0) OP2 always released
ON
Left and right differential lock: Not

OFF Released
installed
4 OP4
ON Left and right differential lock: Installed Connected
OFF
ON
OFF
ON
SW6
OFF
3 Not used (always set to 0) Not needed
ON
OFF
4 Not used (always set to 0) Not needed
ON
• The condition of each switch and connector can be checked with the special function of the machine monitor (monitoring
function).
• Connector OP7 is used for the special function of the machine monitor.
• For details, See SPECIAL FUNCTIONS OF MACHINE MONITOR.
HM400-1L 20-73 1
12
★ All setting operations are carried out with the ignition switch OFF and the monitor panel removed.
• Always set each switch and connector as instructed.
• Be careful not to touch anything inside the grommet except for the switch.
• When turning the rotary switch, use a precision cross-head screwdriver and turn slowly.
• The protruding triangular part of the rotary switch is the setting arrow.
• When changing the dip switch, use a precision flat-headed screwdriver and turn slowly.
• When setting, always avoid foreign matters or dust.
• After setting, be sure to install grommet.
★ Setting Rotary Switch SW1

• Rotary switch SW1 is used to set the travel speed compensation. The machine monitor uses the size of the standard tire to
calculate the travel speed.
• If the tire size is changed, adjust the position of the switch to compensate for the speed display.
★ Tire Size And Setting Position
Tire size SW1 Connector Remarks
29.5 R25 7 Not needed HM400-1 standard tire
• The connector in the table indicates the number of the connector to be connected or released when changing the setting.
(In the case of SW1, there is no need to connect or release the connector.)
★ Travel Speed Compensation Using SW1
Position Speed compensation Position Speed compensation
0 +7% 8 0%
1 +6% 9 -1%
2 +5% A -2%
3 +4% B -3%
4 +3% C -4%
5 +2% D -5%
6 +1% E -6%
7 0% F -7%
A. Rotary switch SW2 is set as follows. The setting must not be changed.
• Set position of SW2: 0
• Connector OP3: Released
A. Rotary switch SW3 is set as follows. The setting must not be changed.
• Set position of SW3: 0
• Connector setting: Not needed
20-74 1 HM400-1L
★ Setting Dip switch SW5-1
• Dip switch SW5-1 is set as follows. The setting must not be changed.
Monitor Part No SW5-1 Connector Remarks
7831-46-100* OFF Distance: Displayed in km

Not Needed
7861-46-200* ON Distance: Displayed in Miles
• The connector in the table indicates the number of the connector to be connected or released when changing the setting.
(In the case of SW5-1, there is no need to connector or release the connector.)
• Use dip switch SW5-2 to set the exhaust brake.
• When the exhaust brake has been installed or removed, set as follows.
Exhaust brake SW5-2 Connector OP1 Remarks
Not installed OFF Released
Installed ON Connected

• Set position of dip switch SW5-3: OFF
• Use dip switch SW5-4 to set the left and right differential lock.
• When the left and right differential lock has been installed or removed, set as follows.
Left and right SW5-2 Connector OP4 Remarks

differential lock
Not installed OFF Released
Installed ON Connected

• Connector operation: Not needed
• Connector operation: Not needed
HM400-1L 20-75 1
TESTING AND ADJUSTING FUNCTIONS OF MACHINE MONITOR
12
FUNCTIONS OF MACHINE MONITOR
NORMAL AND THE SPECIAL FUNCTIONS OF MACHINE MONITOR

The machine monitor is equipped with normal functions and special functions. Various items of data are displayed on the char-
acter display in the middle of the machine monitor. The display items are divided by the internal setting of the machine moni-
tor, into automatic display items and items displayed when the machine monitor switches are operated.
★ Normal functions: Operator Mode
• Functions for which the content is normally displayed or which can be displayed and operated by the operator
operating the switches.
★ Special functions 1: Service Mode 1
• Functions which the serviceman can display and operate with the special switches to carry out inspection,
maintenance, and troubleshooting.
★ Special functions 2: Service Mode 2
• When the machine monitor has been replaced, functions from Service mode 1 can be further displayed and operated
with the special switches
Operator Mode Service Mode 1 Service Mode 2

Service meter, odometer display Electrical system trouble data
1 8 15 Service meter setting function
function (default) display function
Distance traveled in reverse Mechanical system trouble data
2 9 16 Odometer setting function
display function display function
Filter, oil replacement interval Distance traveled in reverse
3 10 Machine data monitoring function 17
display function setting function
4 Telephone number input function 11 Reduced cylinder mode
5 Language selection function 12 Adjustment function
Filter, oil replacement time setting
6 Action code display function 13
function
Initialize function (exclusive
7 Failure code display function 14
function for factory)
20-76 1 HM400-1L
FLOW OF MODES AND FUNCTIONS
HM400-1L 20-77 1
12
Operator Mode
★ No. 2 - No. 5 give an endless display according to the operation of the switch.
★ When a failure occurs, the screen changes automatically to No. 6, regardless of the display screen.
★ Regardless of the display screen, if no switch is operated for more than 30 seconds, the screen automatically changes as
follows.
• Goes to No. 1: If there is no failure
• Goes to No. 6: If there is a failure
★ From No. 7 the screen changes to No. 1 with the switch operation, and if no switch is operated for more than 10 seconds,
the screen automatically changes to No. 6.
Service Mode 1
★ Once the ID is input and confirmed, it remains effective until the ignition switch is turned OFF.
Service Mode 2
Character Display
The character display consists of a top line and bottom line with 16
characters each. A combination of the following characters (alphabet
and numerals) and symbols is displayed according to the content.
• Numerals: 1, 2, 3...
• Small letters: a, b, c...
• Capital letters: A, B, C...
• Symbols: @, $...
• Special characters
Control Switches
Control of the machine monitor display is all carried out with machine
monitor mode selector switches (1) and (2).
• The following functions are provided for the buttons of each

switch.
: Select, Run
: Cancel, Release, Select (YES/NO only)
>: Right, Next, Continue
<: Left, Previous, Return
20-78 1 HM400-1L
12
OPERATION AND DISPLAYS FOR OPERATOR MODE
1. Service Meter, Odometer Display Function
When the ignition switch is turned ON, the top line shows the
service meter and the bottom line shows the odometer (Fig. 1)
• For details, see STRUCTURE AND FUNCTION,
Machine monitor system.
2. Distance Traveled In Reverse Display Function

Use the switch to display the total distance traveled in reverse
of the machine monitor (Fig. 2)
3. Filter, Oil Replacement Interval Display Function
A. Filter, oil replacement time display (automatic display)

• When the replacement interval for the filters or oil
approaches, this information is automatically displayed on
the machine monitor to recommend the operator to carry
out maintenance (Fig. 3: example).
B. Resetting replacement time (selection menu)

• When the maintenance operation for the filters and oil
replacement has been completed, the switches on the
machine monitor can be used to reset the interval (Fig. 4)
• The replacement time can be set using Service mode
1.
4. Telephone Number Input Function

The telephone number set inside the machine monitor can be
input, corrected, or canceled by operating the switches (Fig. 5).
• When action code [E03] is displayed, the telephone
number is displayed at the same time as [CALL].
5. Language Selection Function

The language used for the machine monitor display can be
selected by operating the switches (Fig. 6)
• The functions of Service mode 1 and Service mode 2 are
not included in the functions for display selection, so they
are always displayed in English.
HM400-1L 20-79 1
6. Action Code Display Function
If any abnormality occurs on the machine, the degree of the
abnormality is automatically displayed as a user code on the
machine monitor to recommend appropriate action to the
operator (Fig. 7).
• The diagram on the right shows an example of action code
[E03] and [CALL+ Telephone number] being displayed in
turn.
• When action codes [E01] and [E02] are displayed,
[CALL+ Telephone number] is not displayed.
• Correspondence between user code and recommendation
to operator
Action code CALL+ Telephone number Action recommended to operator
• Carry out inspection and maintenance after completion

E01 Not displayed of operations or when changing shifts between
operators
• When overrun related display is shown:

Reduce engine speed and machine speed while
continuing operations.
E02 Not displayed • When overheat related display is shown:
Stop machine and keep engine running at mid-range
speed under no load.
• Stop engine and machine immediately and contact

E03 Displayed
serviceman.
7. Failure Code Display Function

While the action code is being displayed on the machine
monitor, press the [>] button once to display the failure codes
for the existing failures (Fig. 8: example).
[>] Button: Displays failure code
• The failure codes detected in the past are divided into failures
of the electrical system and the mechanical system and are
recorded as trouble data. (For details, see Service mode 1.)
• If more than one failure is occurring, press the [>] button once
more to display the other failure codes.
• After pressing the [>] button to display all the existing failures,
press the [>] button once more to return to the service meter/
odometer display screen.
• If the [>] button is pressed once more, the failure codes will be
displayed again from the beginning.
• If the switch is not operated for 10 seconds, the display will
switch automatically to the action code screen.
• With the service code display function, the following data are
displayed (Fig. 9).
A: Failure code
(4 digits for location code + 2 digits for problem code)
B: Controller code
• (MON: Machine monitor)
• (ENG: Engine controller)
• (TM: Transmission controller)
• (BK: Retarder controller)
20-80 1 HM400-1L
C: System with problem
• For details of the displayed failure codes, see FAILURE CODE TABLE.
• With the failure code display function and trouble data display function (Service mode 1), the data that are displayed
are partially different.
• If no switch is operated on the failure code display screen for more than 30 seconds, the display automatically returns
to the action code display screen.
Failure Code Table
Location of failure Nature of failure

Failure code Controller Action code
(location, component with failure) (problem, nature of failure)
1380MW Lock-up clutch Slipping (MW) TM E03
1500LO Transmission clutch * See separate table (L0) TM E03
15BONX Transmission oil filter Clogged (NX) TM E01
15GOMW R clutch Slipping (MW) TM E03
15HOMW Hi clutch Slipping (MW) TM E03
15JOMW Lo clutch Slipping (MW) TM E03
15KOMW 1st clutch Slipping (MW) TM E03
15LOMW 2nd clutch Slipping (MW) TM E03
15MOMW 3rd clutch Slipping (MW) TM E03
15SBL1 ECMV for R clutch * See separate table (L1) TM E03
15SBMA ECMV for R clutch Function impossible (MA) TM E03
15SCL1 ECMV for Hi clutch * See separate table (L1) TM E03
15SCMA ECMV for Hi clutch Function impossible (MA) TM E03
15SDL1 ECMV for Lo clutch * See separate table (L1) TM E03
15SDMA ECMV for Lo clutch Function impossible (MA) TM E03
15SEL1 ECMV for 1st clutch * See separate table (L1) TM E03
15SEMA ECMV for 1st clutch Function impossible (MA) TM E03
15SFL1 ECMV for 2nd clutch * See separate table (L1) TM E03
15SFMA ECMV for 2nd clutch Function impossible (MA) TM E03
5SGL1 ECMV for 3rd clutch * See separate table (L1) TM E03
15SGMA ECMV for 3rd clutch Function impossible (MA) TM E03
15SJL1 ECMV for lock-up clutch * See separate table (L1) TM E03
15SJMA ECMV for lock-up clutch Function impossible (MA) TM E03
15SKL1 ECMV for inter-axle differential lock clutch * See separate table (L1) TM E03
15SKMA ECMV for inter-axle differential lock clutch Function impossible (MA) TM E01
2A62L1 Front wheel differential lock control valve * See separate table (L1) BK E01
2A62LH Front wheel differential lock control valve * See separate table (LH) BK E01
2B61MW Inter-axle differential lock clutch Slipping (MW) TM E01
2B62L1 Rear wheel differential lock control valve * See separate table (L1) BK E01
2B62LH Rear wheel differential lock control valve * See separate table (LH) BK E01
2C4MNX Brake cooling filter Clogged (NX) BK E01
2D01CA Front brake (right) Wear (CA) BK E01
2D02CA Front brake (left) Wear (CA) BK E01
2D03CA Center brake (right) Wear (CA) BK E01
2D04CA Center brake (left) Wear (CA) BK E01
2D05CA Rear brake (right) Wear (CA) BK E01
2D06CA Rear brake (left) Wear (CA) BK E01
Mistaken operation or mistaken
2F00KM Parking brake TM -
setting (KM)
2G42ZG Accumulator (front) Drop in oil pressure (ZG) BK E03
2G43ZG Accumulator (rear) Drop in oil pressure (ZG) BK E03
HM400-1L 20-81 1
12

6014NX Hydraulic tank filter Clogged (NX) TM E01
989A00 Engine overrun prevention command signal Actuated (OO) TM E02
989AKZ Engine overrun prevention command signal Disconnection or short circuit (KZ) TM E01
989D00 Rear overturn signal Actuated (OO) TM -
A00N1 Engine Overrun (N1) ENG E02
A570NX Engine oil filter Clogged (NX) ENG E01
AA10NX Air cleaner element Clogged (NX) TM E01
AB00MA Alternator Function impossible (MA) TM E03
AD00L2 Common rail * See separate table (L2) ENG E03
AD00MA Common rail Function impossible (MA) ENG E03
AD10L3 Fuel supply pump * See separate table (L3) ENG E03
AD10MA Fuel supply pump Function impossible (MA) ENG E03
AD10MB Fuel supply pump Drop in function (MB) ENG E03
AD11KA Fuel supply pump solenoid valve 1 Disconnection (KA) ENG E03
AD11KB Fuel supply pump solenoid valve 1 Short circuit (KB) ENG E03
AD51KA Fuel supply pump solenoid valve 2 Disconnection (KA) ENG E03
AD51KB Fuel supply pump solenoid valve 2 Short circuit (KB) ENG E03
ADA1KA No. 1 injector solenoid valve Disconnection (KA) ENG E03
ADAZKB No. 1, 2, 3 injector solenoid valve Short circuit (KB) ENG E03
ADB1KA No. 2 injector solenoid valve Disconnection (KA) ENG E03
ADC1KA No. 3 injector solenoid valve Disconnection (KA) ENG E03
ADD1KA No. 4 injector solenoid valve Disconnection (KA) ENG E03
ADDZKB No. 4, 5, 6 injector solenoid valve Short circuit (KB) ENG E03
ADE1KA No. 5 injector solenoid valve Disconnection (KA) ENG E03
ADF1KA No. 6 injector solenoid valve Disconnection (KA) ENG E03
B@BAZG Engine oil Drop in oil pressure (ZG) ENG E03
B@BAZK Engine oil Drop in level (ZK) ENG E01
B@BAZG Radiator coolant Overheat (NS) ENG E02
B@BCZK Radiator coolant Drop in level (ZK) TM E01
B@C6NS Front brake oil Overheat (NS) MON E02
B@C7NS Rear brake oil Overheat (NS) MON E02
B@C8NS Center brake oil Overheat (NS) MON E02
B@CENS Torque converter Overheat (NS) MON E02
B@HAZK Hydraulic tank oil Drop in level (ZK) TM E01
B@JANS Steering oil Overheat (NS) TM E02
D181KZ Preheating relay contact Disconnection or short circuit (KZ) ENG E03
D182KZ Preheating relay coil Disconnection or short circuit (KZ) ENG E03
D1B0KZ Transmission cut relay Disconnection or short circuit (KZ) TM E03
D1C0KZ Brake cut relay Disconnection or short circuit (KZ) BK E03
D1D0KB Engine controller load power source relay Short circuit (KB) ENG E01
20-82 1 HM400-1L
12
D5ZAKX Engine throttle correction 1 signal Input signal outside range (KX) ENG E01
D5ZBKX Inter-axle differential lock command signal Input signal outside range (KX) TM E01
D5ZCKZ Exhaust brake command signal Disconnection or short circuit (KZ) TM E01
D5ZDL4 Forced neutral demand signal * See separate table (L4) TM E01
D5ZEKX Engine load signal Input signal outside range (KX) TM E01
D5ZFKZ Neutral signal 1 Disconnection or short circuit (KZ) BK E01
D5ZGKZ Neutral signal 2 Disconnection or short circuit (KZ) BK E01
Mistaken operation or mistaken setting
(DAF0KM) Monitor panel MON E03
(KM)
DAF9KM) Monitor panel MON E03
(KM)
DAFSKZ Monitor panel Non match in model selection signal (KQ) MON E03
DAQ0KK Transmission controller Drop in power source voltage, input (KK) TM E03
DAQ1KK Transmission controller main power supply line Drop in power source voltage, input (KK) TM E03
DAQ2KK Transmission controller load power supply line Drop in power source voltage, input (KK) TM E03
Transmission controller battery direct power
DAQ3KK Drop in power source voltage, input (KK) TM E03
supply line
DAQ5KP Transmission controller power supply output 1 Drop in output voltage (KP) TM E03
(DAQ9KM) Transmission controller wiring harness Mistaken operation or mistaken setting (KP) TM E03
(DAQ9KQ) Transmission controller wiring harness Non match in model selection signal (KQ) TM E03
(DAQAKQ) Transmission controller rotary switch Non match in model selection signal (KQ) TM E03
Defective transmission, abnormality in
DAQSKR Transmission controller S-NET MON E03
applicable component system (KR)
DAQSMA Transmission controller Function impossible (MA) TM E03
DB10KK Retarder controller (❄1) Drop in power source voltage, input (KK) BK E03
DB11KK Retarder controller (❄1) main power supply line Drop in power source voltage, input (KK) BK E03
DB12KK Retarder controller (❄1) load power supply line Drop in power source voltage, input (KK) BK E03
Retarder controller (❄1) battery direct power
DB13KK Drop in power source voltage, input (KK) BK E03
supply line
(DB19KM) Retarder controller (❄1) wiring harness BK E03
(KM)
DB1SKQ Retarder controller (❄1) S-NET line Non match in model selection signal (KQ) BK E03
DB1SKR Retarder controller (❄1) S-NET MON E03
DB20KK Engine controller Drop in power source voltage, input (KK) ENG E03
DB20KT Engine controller Abnormality inside controller (KT) ENG E03
DB22KK Engine controller load power supply line Drop in power source voltage, input (KK) ENG E03
DB29KQ Engine controller connecting wiring harness Non match in model selection signal (KQ) ENG E03
Engine controller fuel injection quantity control
DB2AMA Function impossible (MA) ENG E01
switch
DB2SKR Engine controller S-NET MON E03
DD11KB Ignition switch Short circuit (KB) ENG E03
DDA1L5 Accelerator switch * See separate table (L5) ENG E01
DDE2L6 Engine oil pressure switch * See separate table (L6) ENG E01
DDTFKA Fill switch for inter-axle differential lock clutch Disconnection (KA) TM E01
DDTGKA Fill switch for lock-up clutch Disconnection (KA) TM E03
DDTHKA Fill switch for Hi clutch Disconnection (KA) TM E03
DDTJKA Fill switch for Lo clutch Disconnection (KA) TM E03
❄ 1.Used as the brake controller in E-SPEC.
HM400-1L 20-83 1

DDTKKA Fill switch for 1st clutch Disconnection (KA) TM E03
DDTLKA Fill switch for 2nd clutch Disconnection (KA) TM E03
DDTMKA Fill switch for 3rd clutch Disconnection (KA) TM E03
DDTNKA Fill switch for R clutch Disconnection (KA) TM E03
DF10KA Gearshift lever Disconnection (KA) TM E03
DF10KB Gearshift lever Short circuit (KB) TM E03
Engine coolant temperature sensor (for high
DGE2KX Input signal outside range (KX) ENG E01
temperature)
Engine coolant temperature sensor (for low
DGE3L6 * See separate table (L6) ENG E01
temperature)
DGE4KX Fuel temperature sensor Input signal outside range (KX) ENG E01
DGF1KX Transmission valve oil temperature sensor Input signal outside range (KX) TM E03
DGR2L8 Brake oil temperature sensor (rear) * See separate table (L8) TM E01
DGR3L8 Brake oil temperature sensor (center) * See separate table (L8) TM E01
DGR4L8 Brake oil temperature sensor (front) * See separate table (L8) TM E01
DGT1KX Torque converter oil temperature sensor Input signal outside range (KX) TM E01
DH30KX Boost pressure sensor Input signal outside range (KX) ENG E01
DH40KX Common rail pressure sensor Input signal outside range (KX) ENG E03
DHT5KX Torque converter oil pressure sensor Input signal outside range (KX) TM E01
DHT5L6 Torque converter oil pressure sensor * See separate table (L6) TM E01
DHU2KX Accumulator oil pressure sensor (front) Input signal outside range (KX) BK E01
DHU3KX Accumulator oil pressure sensor (rear) Input signal outside range (KX) BK E01
DJF1KA Fuel level sensor Disconnection (KA) TM E01
DK10KX Throttle angle sensor Input signal outside range (KX) ENG E03
DK11KX Throttle angle sensor Input signal outside range (KX) TM E03
DK51L5 Retarder lever potentiometer * See separate table (L5) BK E03
DK52KX Dump lever potentiometer 1 Input signal outside range (KX) BK E03
DK53L8 Dump lever potentiometer 2 * See separate table (L8) BK E03
DK54KX Body position sensor Input signal outside range (KX) BK E03
DLE2KA Engine speed sensor Disconnection (KA) TM E03
DLE2LC Engine speed sensor * See separate table (LC) TM E03
DLE3LC Engine Ne speed sensor * See separate table (LC) ENG E03
DLF1KA Transmission input shaft speed sensor Disconnection (KA) TM E03
DLF1LC Transmission input shaft speed sensor * See separate table (LC) TM E03
DLF2KA Transmission intermediate shaft speed sensor Disconnection (KA) TM E03
DLF2LC Transmission intermediate shaft speed sensor * See separate table (LC) TM E03
DLT4KA Transmission output shaft F speed sensor Disconnection (KA) BK E01
DLH1LC Engine G speed sensor * See separate table (LC) ENG E03
DLT3KA Transmission output shaft R speed sensor Disconnection (KA) TM E03
DLT3KA Transmission output shaft R speed sensor Disconnection (KA) BK E01
DLT3LC Transmission output shaft R speed sensor Separate table (LC) TM E03
20-84 1 HM400-1L
12

DV00KB Alarm buzzer Short circuit (KB) MON E01
DW71KZ Exhaust brake solenoid Disconnection or short circuit (KZ) BK E01
DW72KZ Dump lever kick-out solenoid Disconnection or short circuit (KZ) BK E01
DW73KZ Dump selector valve solenoid Disconnection or short circuit (KZ) BK E03
DX11KA Rear brake reducing pressure valve solenoid Disconnection (KA) BK E03
DX11KB Rear brake reducing pressure valve solenoid Short circuit (KB) BK E03
DX11KY Rear brake reducing pressure valve solenoid Short circuit in power supply line ((KY) BK E03
DX12KA Front brake reducing pressure valve solenoid Disconnection (KA) BK E03
DX12KB Front brake reducing pressure valve solenoid Short circuit (KB) BK E03
DX12KY Front brake reducing pressure valve solenoid Short circuit in power supply line ((KY) BK E03
DX13KA Dump EPC valve solenoid Disconnection (KA) BK E03
DX13KB Dump EPC valve solenoid Short circuit (KB) BK E03
DX13KY Dump EPC valve solenoid Short circuit in power supply line ((KY) BK E03
DX14KZ Rear wheel differential lock solenoid Disconnection or short circuit (KZ) BK E03
DX15KZ Front wheel differential lock solenoid Disconnection or short circuit (KZ) BK E03
DXH0KA Solenoid for inter-axle differential lock Disconnection (KA) TM E01
DXH0KB Solenoid for inter-axle differential lock Short circuit (KB) TM E01
DXH1KA Solenoid for lock-up clutch Disconnection (KA) TM E03
DXH1KB Solenoid for lock-up clutch Short circuit (KB) TM E03
DXH2KA Solenoid for Hi clutch Disconnection (KA) TM E03
DXH2KB Solenoid for Hi clutch Short circuit (KB) TM E03
DXH3KA Solenoid for Lo clutch Disconnection (KA) TM E03
DXH3KB Solenoid for Lo clutch Short circuit (KB) TM E03
DXH4KA Solenoid for 1st clutch Disconnection (KA) TM E03
DXH4KB Solenoid for 1st clutch Short circuit (KB) TM E03
DXH5KA Solenoid for 2nd clutch Disconnection (KA) TM E03
DXH5KB Solenoid for 2nd clutch Short circuit (KB) TM E03
DXH6KA Solenoid for 3rd clutch Disconnection (KA) TM E03
DXH6KB Solenoid for 3rd clutch Short circuit (KB) TM E03
DXH7KA Solenoid for R clutch Disconnection (KA) TM E03
DXH7KB Solenoid for R clutch Short circuit (KB) TM E03
HM400-1L 20-85 1
12
Detailed phenomena of L Series problem codes (L*)
Problem code Nature
L0 Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF
L2 Fuel pressure is higher than maximum set pressure
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match
L5 Potentiometer signal and switch signal do not match
Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature
L6
switch, etc. do not match operating condition or stopped condition of machine
L8 Analog signals for 2 systems do not match
LC Speed signals for 2 systems do not match
LH Fill signal is OFF when command current to ECMV is ON
★ Failure codes with ( )

These failure codes are not recorded as trouble data for either the electrical system or the mechanical system.
★ Controller codes and troubleshooting mode names
The controller code name shown in the Controller column and the troubleshooting mode name in the troubleshooting
section are linked, so check the controller code for the failure code displayed, then go to the applicable
troubleshooting mode.
• ENG: Troubleshooting of engine controller system (ENG MODE)
• TM: Troubleshooting of transmission controller system (TM MODE)
• BK: Troubleshooting of retarder controller (❄1) system (BK MODE)
• MON: Troubleshooting of machine monitor system (MON MODE)
❄1. Used as the brake controller in E-SPEC.
20-86 1 HM400-1L
12
SWITCHING TO SERVICE MODE 1 AND SCREEN DISPLAY
★ When using Service mode 1, carry out the following special operation to switch the screen display.
1. Checking Screen Display

With the machine monitor in the operator mode, check that the screen is one of the following displays:
Service meter/odometer, action code, or failure code.
2. Initial Screen Display For ID Input

Press the following 2 buttons at the same time for at least 5
seconds to display the initial screen display for the ID input
(Fig. 1).
• [ ] button and [<] button
• If the buttons are held pressed for at least 5 seconds, the
whole screen will give no display, so check this condition,
then release the buttons.
3.Inputting ID, Confirming

Operate the buttons to input the ID (Fig. 2).
★ ID: 6491
[>] button: Number at cursor goes up
[<] button: Number at cursor goes down
[ ] button: Number at cursor is confirmed
[ ] button: Returns to initial screen (see Note)
• When the cursor is at the left side, the screen returns to the normal
screen (operator mode). If the cursor is not at the left side, the
cursor returns to the left side.
• If the switch on the ID input screen is not operated for more than 60 seconds, the screen returns automatically to the
normal screen.
4. Displaying Menu Initial Screen

After confirming all four digits of the ID, the menu initial
screen of Service mode 1 is displayed (Fig. 3).
Once the ID has been input and confirmed, it remains effective
until the ignition switch is turned OFF.
5. Menu Selection In Service Mode 1

Press the [>] or [<] buttons on the menu screen and the menus
of Service mode 1 are displayed endlessly in the following
order (Fig. 4).
• The menu is displayed in the places marked with [*].
• [>] button: Goes on to next menu
• [<] button: Goes back to previous menu
(1) ELECTRICAL FAULT: Trouble data display function
for electrical system
(2) MACHINE FAULT: Trouble data display function for mechanical system
(3) REAL-TIME MONITOR: Machine data monitoring function
(4) CYLINDER CUT-OUT: Reduced cylinder mode
(5) TUNING: Adjustment function
(6) MAINTENANCE MONITOR: Filter, oil replacement time setting function
(7) INITIALIZE: Initialize function (exclusive function for factory)
HM400-1L 20-87 1
6. Completion Of Mode, Function
When operating at any point in any function, it is possible to finish the mode or function by using any of the
following methods.
A. When continuing operations in another mode or function:

Press the [ ] button and return to the mode screen to be used or menu screen to be used.
• Note that if the [ ] button is pressed on the YES/NO screen, the function will be executed.
• If you return to the normal screen (operator mode) by mistake, repeat the procedure from Step 1) above (there is
no need to input the ID again).
B. When completing all operations:

Turn the ignition switch OFF.
7. Electrical System Trouble Data Display Function (ELECTRIC

FAULT)
The machine monitor retains the data for problems that
occurred in the electrical system in the past as failure codes.
They can be displayed as follows.
A. Menu Selection
• Select the display function for trouble data on the menu
screen of Service mode 1 (Fig. 1).
• The total number of trouble data items recorded in memory is displayed in the [**] portion.
B. Trouble Data Display

• With the menu selected, press the [ ] button and display
the trouble data recorded in memory (Fig. 2: example).
• [ ] button: Runs menu
C. Displayed Trouble Data

• With the display function for trouble data of the electrical
system, the following data can be displayed (Fig. 3).
1: Record number (recorded up to a maximum of 20
items)
A: Failure code (4-digit location code + 2-digit problem
code)
2: Number of occurrences (number of occurrences of
same code in past)
3: Elapsed time 1 (time elapsed on service meter since first occurrence)
4: Elapsed time 2 (time elapsed on service meter since last occurrence)
★ Failure codes for problems that are still existing are shown on a flashing display.
★ For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code display
function.
★ Note that with the trouble data display function and failure code display function for the electrical system, the displayed
data are partially different.
★ If no trouble data are recorded, [0] is displayed on the display portion for 1, and [-] is displayed on the display portion for
A, 2, 3, and 4.
D. Switching Trouble Data Display

• If the [>] button or [<] button is pressed during the display of trouble data, the display switches to the other
recorded trouble data.
• [>] button: Goes on to data for next record number
20-88 1 HM400-1L
• [<] button: Goes back to data for last record number
E. Deleting Individual Trouble Data

• Display the trouble data to be deleted, then press the [ ]
button once to display the individual item CLEAR screen
(Fig. 4).
[ ] button: Display CLEAR screen
• Operate the buttons according to the explanation on the
screen (Fig. 4).
[<] button: Select YES
[>] button: Select NO
[ ] button: Run
★ The data for an existing problem (flashing display) cannot be deleted.
F.
Deleting All Trouble Data
• Display the trouble data, then press the [>] button or [<]
button to display the ALL CLEAR menu (Fig. 5).
• Press the [ ] button once to display the ALL CLEAR
screen (Fig. 6).
• [ ] button: Run ALL CLEAR menu
• Operate the buttons according to the explanation on the
screen (Fig. 6).
• [ ] button: Run
★ The data for an existing problem (flashing display) cannot be
deleted.
8. Mechanical System Trouble Data Display Function

(MACHINE FAULT)
The machine monitor retains the data for problems that
occurred in the electrical system in the past as failure codes.
They can be displayed as follows.
A. Menu Selection
• Select the display function for trouble data on the menu
• The total number of trouble data items recorded in memory is displayed in the [**] portion.
B. Trouble Data Display

the trouble data recorded in memory (Fig. 2: example).
C. Displayed Trouble Data

• With the display function for trouble data of the
mechanical system, the following data can be displayed
(Fig. 3).
1: Record number
A: Failure code (4-digit location code + 2-digit problem code)
2: Number of occurrences (number of occurrences of same code in past)
HM400-1L 20-89 1
3: Elapsed time 1 (time elapsed on service meter since
first occurrence)
4: Elapsed time 2 (time elapsed on service meter since
last occurrence)
★ Failure codes for problems that are still existing are shown on a
flashing display.
★ For details of the failure codes displayed, see FAILURE CODE
TABLE in the explanation for the failure code display function.
★ Note that with the trouble data display function and failure code
display function for the mechanical system, the displayed data are partially different.
★ If no trouble data are recorded, [0] is displayed on the display portion for 1, and [-] is displayed on the display portion for
A, 2, 3, and 4.
D. Switching Trouble Data Display

• If the [>] button or [<] button is pressed during the display of trouble data, the display switches to the other
recorded trouble data.
[>] button: Goes on to data for next record number
[<] button: Goes back to data for last record number
E. Deleting trouble data (not permitted)

• The trouble data for the mechanical system cannot be deleted.
9. Machine Data Monitoring Function (Real-time Monitor)

• The machine monitor can monitor the condition of the machine
in real time through the signals from the sensors installed to
various parts of the machine.
• In the machine data monitoring function, the following 2 types of
display can be shown.
• 1st item independent display (for each controller)
• 2nd item simultaneous display (code input)
A. Menu Selection
• Select the machine data monitoring function on the menu
B. Display sub menu

the initial screen of the sub menu (Fig. 2).
C. Select Sub Menu

• If the [>] button or [<] button is pressed on the sub menu
screen, the sub menu displays endlessly in the following
order (Fig. 3).
• The sub menu is displayed in the [*] portion.
[>] button: Goes on to next menu
[<] button: Goes back to last menu
(1) MONITOR PANEL: Machine monitor system
(2) TRANSMISSION: Transmission controller system
(3) ENGINE: Engine controller system
(4) BRAKE: Retarder controller system
(5) 2 ITEMS: 2-item display
20-90 1 HM400-1L
D. Setting 1st Item Individual Monitoring
i. Select the controller system for monitoring on the sub

menu screen (Fig. 4: example).
ii. With the menu selected, press the [ ] button and display
the monitoring data initial screen.
• [ ] button: Runs sub menu
iii. Press the [>] button or [<] button to select the item for
monitoring (Fig. 5: example).
• [>] button: Goes on to next item
• [<] button: Goes back to last item
• Scroll the monitoring items to display in the internally set
order.
• If the button is kept pressed, the items will scroll at high speed.
★ To hold or cancel monitoring data:
If the [ ] button is pressed during monitoring, the monitor
data is held and the [ ] mark flashes. If the [ ] button is
pressed again, it becomes active again.
E. Display Data For 1st Item Individual Monitoring

• On the 1st item individual monitoring screen, the
following data are displayed (Fig. 6).
A: Item display
B: Monitoring code (5-digit)
1: Monitoring data (including unit)
For details, see MONITORING CODE TABLE.
F. Setting 2nd Item Simultaneous Monitoring
i. Select the 2nd item display on the sub menu screen (Fig.
6).
ii. With the menu selected, press the [ ] button and display
the monitoring code input screen (Fig. 7).
• [ ] button: Runs sub menu
iii. Operate each button and input the monitoring code for the
2nd monitoring item directly.
• [>] button: Number at cursor goes up
• [<] button: Number at cursor goes down
• [ ] button: Number at cursor is confirmed
• [ ] button: Returns to code input screen
iv. When both of the monitoring codes have been confirmed,

the screen switches to the 2nd item display screen (Fig. 9:
example).
HM400-1L 20-91 1
★ To hold or cancel monitoring data:
If the [ ] button is pressed during monitoring, the monitor
data is held and the [ ] mark flashes. If the [ ] button is
pressed again, it becomes active again.
G. Display Data For 2nd Item Simultaneous Monitoring

• On the 2nd item simultaneous monitoring screen, the
following data are displayed (Fig. 5).
A: Monitoring code 1
1: Monitoring data 1 (including unit)
B: Monitoring code 2
2: Monitoring data 2 (including unit)
★ For details, see MONITORING CODE TABLE.
Monitoring Code Table
MONITOR PANEL [Monitor panel system]

Monitoring
No. Monitoring item Item display Display range Unit
code
1 Engine speed ENG SPEED 01001 0 - 65535 rpm
2 Engine coolant temperature (for high temperature) COOLANT TEMP H 04102 0 - 160 o
C
3 Torque converter oil temperature T/C OIL TEMP 30100 0 - 160 oC
4 Brake oil temperature BRAKE OIL TEMP 30200 0 - 160 o

C
5 Fuel level sensor input resistance value FUEL SENSOR 04201 0 - 150 Ω
6 Rheostat input voltage RHEOSTAT 30300 0.0 - 51.0 V
7 Operation status of AISS switch AISS SW 30400 ON/OFF Status display
UPPER/
8 Operation status of exhaust brake switch EXH BRAKE SW 30500 NEUTRAL/ Status display
LOWER
UPPER/
9 Operation status of inter-axle differential lock switch INTER AXLE SW 30600 Status display
LOWER
UPPER/
10 Operation status of left and right differential lock switch L-R DIFF SW 30610 NEUTRAL/ Status display
LOWER
11 Operation status of left and right differential lock pedal FOOT DIFF SW 30620 ON/OFF Status display
ON/OFF, ON/
12 Input status of connector check (1 & 2) CONN CHK 1, 2 30700 Status display
OFF
0 - F, 0 - F, 0 -
13 Setting status of rotary switch (SW1 & SW2 & SW3) SW1, SW2, SW3 30800 Status display
F,
ON/OFF, ON/
14 Setting status of dip switch (SW5-1 & SW5-2) SW5-1, SW5-2 30900 Status display
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
18 Setting status of option selection connector (OP1 & OP2) OPTION 1, 2 31000 Status display
OFF
ON/OFF, ON/
OFF
ON/OFF, ON/
OFF
★ The following monitoring items display data for 2 or 3 systems at the same time.
No. 12: Input status of connector check (displays 2 items)
No. 13: Setting status of rotary switch (displays 3 items at same time)
20-92 1 HM400-1L
No. 14: Setting status of dip switch (displays 2 items at same time)
No. 18: Setting status of option selection connector (displays 2 items at same time)
TRANSMISSION [Transmission controller system]

Monitoring
No. Monitoring item Item display display range Unit
code
1 Transmission service meter SERVICE METER 31100 0 - 65535 h
2 Transmission input shaft speed T/M SPEED: IN 31200 0 - 65535 rpm
3 Transmission intermediate shaft speed T/M SPEED: MID 31300 0 - 65535 rpm
4 Transmission output shaft (R) speed T/M SPEED: OUT 31400 0 - 65535 rpm
5 Actuation status of Lo clutch fill switch FILL SW (L) 31510 ON/OFF Status display
6 Actuation status of Hi clutch fill switch FILL SW (H) 31511 ON/OFF Status display
7 Actuation status of 1st clutch fill switch FILL SW (1st) 31512 ON/OFF Status display
8 Actuation status of 2nd clutch fill switch FILL SW (2nd) 31513 ON/OFF Status display
9 Actuation status of 3rd clutch fill switch FILL SW (3rd) 31514 ON/OFF Status display
10 Actuation status of R clutch fill switch FILL SW (R) 31516 ON/OFF Status display
11 Actuation status of L/U clutch fill switch FILL SW (L/U) 31509 ON/OFF Status display
Actuation status of transmission differential lock clutch fill FILL SW (DIFF) 31517 ON/OFF Status display
12
switch
13 Output current command value for Hi clutch solenoid ECMV H DIR 31600 0 - 1020 mA
14 Output current detection value for Hi clutch solenoid ECMV H 31610 0 - 1020 mA
15 Output current command value for Lo clutch solenoid ECMV L DIR 31601 0 - 1020 mA
16 Output current detection value for Lo clutch solenoid ECMV L 31611 0 - 1020 mA
17 Output current command value for 1st clutch solenoid ECMV 1 DIR 31602 0 - 1020 mA
18 Output current detection value for 1st clutch solenoid ECMV 1 31612 0 - 1020 mA
19 Output current command value for 2nd clutch solenoid ECMV 2 DIR 31603 0 - 1020 mA
20 Output current detection value for 2nd clutch solenoid ECMV 2 31613 0 - 1020 mA
21 Output current command value for 3rd clutch solenoid ECMV 3 DIR 31604 0 - 1020 mA
22 Output current detection value for 3rd clutch solenoid ECMV 3 31614 0 - 1020 mA
23 Output current command value for R clutch solenoid ECMV R DIR 31606 0 - 1020 mA
24 Output current detection value for R clutch solenoid ECMV R 31616 0 - 1020 mA
25 Output current command value for L/U clutch solenoid ECMV LU DIR 31609 0 - 1020 mA
26 Output current detection value for L/U clutch solenoid ECMV LU 31619 0 - 1020 mA
Output current command value for transmission ECMV D DIR 31607 0 - 1020 mA
27
differential lock clutch solenoid
Output current detection value for transmission ECMV D 31617 0 - 1020 mA
28
differential lock clutch solenoid
29 Hi clutch fill time FILL TIME H 41801 0 - 2550 ms
30 Lo clutch fill time FILL TIME L 41800 0 - 2550 ms
31 R clutch fill time FILL TIME R 41806 0 - 2550 ms
32 1st clutch fill time FILL TIME 1 41802 0 - 2550 ms
33 2nd clutch fill time FILL TIME 2 41803 0 - 2550 ms
34 3rd clutch fill time FILL TIME 3 41804 0 - 2550 ms
35 Hi clutch fill status FILL H 31501 0-2 Status display
36 Lo clutch fill status FILL L 31500 0-2 Status display
37 R clutch fill status FILL R 31506 0-2 Status display
38 1st clutch fill status FILL 1 31502 0-2 Status display
39 2nd clutch fill status FILL 2 31503 0-2 Status display
HM400-1L 20-93 1
12
MONITOR PANEL [Monitor panel system]
Monitoring
code
40 3rd clutch fill status FILL 3 31504 0-2 Status display
41 Axle sensor input voltage THROTTLE POS 31700 0.00 - 5.10 V
42 Forced neutral command 1 status N DIRECTION 1 31800 ON/OFF Status display
43 Forced neutral command 1 status N DIRECTION 2 31801 ON/OFF Status display
44 Differential lock command voltage INT DIFF SIG 31900 0.00 - 5.10 V
45 Operation status of shift hold switch SHIFT HOLD SW 32000 ON/OFF Status display
ON/OFF, ON/
46 Actuation status of emergency steering (1 & 2) ENERG STRG 1,2 32100 Status display
OFF
47 Input status of alternator terminal R ALTERNATOR R 04301 ON/OFF Status display
48 Input status of ignition switch terminal C KEY SW C 32300 ON/OFF Status display
49 Setting status of emergency escape switch ENERG TRAVEL 32400 ON/OFF Status display
50 ECMV oil temperature ECMV OIL TEMP 32500 0 - 160 oC
51 Torque converter oil pressure T/C OIL PRESS 32600 0.00 - 5.02 MPa
OVERHEAT/
52 Steering oil temperature STRG OIL TEMP 32700 Status display
NORMAL
-0.52 - 0.00 -
53 Tilt angle ANGLE SENSOR 32900 rad
0.37
ON/OFF, ON/
54 Input status of connector check (1 & 2) CONN CHK 1,2 30701 Status display
OFF
LOW/
55 Transmission oil level OIL LEVEL 33000 Status display
NORMAL
LOW/
56 Radiator coolant level COOLANT LEVEL 33100 Status display
NORMAL
CLOGGED/
57 Clogging status of air cleaner AIR CLEANER 33200 Status display
NORMAL
CLOGGED/
58 Clogging status of transmission filter T/M FILTER 33300 Status display
NORMAL
CLOGGED/
59 Clogging status of hydraulic oil filter HYD OIL FILTER 33400 Status display
NORMAL
60 Reverse permission accepted condition REVERSE (DUMP) 33500 OK/NO Status display
61 Engine load signal value ENGINE LOAD 33600 0 - 100 %
62 Setting status of rotary switch (SW1 & SW2) ROTARY SW 1,2 30801 0 - F, 0 - F Status display
63 Input status of model selection wiring harness 1 MACHINE SEL1 02701 GND/OPEN Status display
Note: The following monitoring items display data for 2 systems at the same time.
No. 46: Actuation condition of emergency steering (displays 2 systems at same time)
No. 54: Input status of connector check (displays 2 systems at same time)
No. 62: Setting status of rotary switch (displays 2 items at same time)
20-94 1 HM400-1L
12
ENGINE [Engine controller system]

Monitoring
code
1 Engine speed ENG SPEED 01002 0 - 3000 rpm
2 Accelerator sensor angle THROTTLE POS 31701 0 - 100 %
3 Fuel temperature FUEL TEMP 04203 -30 - 100 oC
4 Transmission throttle correction value MODIFY SIGNAL 36000 -100 - 100 %

5 Axle sensor input voltage THROTTLE POS 31702 0.00 - 5.00 V
6 Target fuel injection level FUEL DELIVERY 36100 -30 - 600 mm³
7 Target common rail pressure RAIL PRESS (C) 36200 0 -150 MPa
8 Target injection timing INJECT TIMING 36300 -30.0 - 31.0 °CA
9 Common rail pressure RAIL PRESS (A) 36400 0 - 150 MPa
10 Boost pressure BOOST PRESS 36500 0 - 300 kPa
11 Operating mode status ENG STATUS 36600 0 - 255 Status display
12 coolant temperature for engine high temperature COOLANT TEMP H 04102 0 - 150 o
C
13 coolant temperature for engine low temperature COOLANT TEMP L 04101 -30 - 100 o
C
14 Converted torque value TORQUE RATIO 36700 0 - 100 %
Setting status of fuel injection quantity control switch (1 &
15 Q ADJUST SW1, 2 36800 0 - F. 0 - F Status display
2)
16 Input status of model selection 1 MACHINE SEL1 02704 GND/OPEN Status display
19 Controller ROM No. ENGINE ROM 20203 Numeral Status display
No. 8 is measured in degrees of crank angle (°CA).
The following monitoring item displays data for 2 systems at the same time.
No. 15: Setting status of fuel injection quantity control switch (displays 2 items at same time)
HM400-1L 20-95 1
BRAKE [Retarder controller (q1) system]

Monitoring
code
1 Brake service meter SERVICE METER 31101 0 - 65535 h
Output current command value for front brake EPC
2 F BK OUTP DIR 33700 0 - 1020 mA
solenoid
Output current detection value for front brake EPC
3 F BRAKE OUTPUT 33701 0 - 1020 mA
solenoid
Output current command value for rear brake EPC
4 R BK OUTP DIR 33800 0 - 1020 mA
solenoid
Output current detection value for rear brake EPC
5 R BRAKE OUTPUT 33801 0 - 1020 mA
solenoid
0.00 - 5.10 0 -
6 Retarder lever (q2) input (voltage & conversion amount) RETARD LEVER 33900 V (%)
100
ON/OFF, ON/
7 Input status of retarder lever (q2) validation switch (1 & 2) RLV SW 1,2 34000 Status display
OFF
WORKING/
8 Operation status of retarder lever (q2) switch RETARDER 34100 Status display
RELEASE
9 Dump lever potentiometer 1 input voltage DUMP LEVER 1 34300 0.00 - 5.10 V
10 Dump lever potentiometer 2 input voltage DUMP LEVER 2 34301 0.00 - 5.10 V
11 Body position sensor input voltage BODY POSITION 34400 0.00 - 5.10 V
12 Input status of body seat switch BODY SEATING 34600 ON/OFF Status display
13 Output status of dump lever solenoid KICKOUT SOL 34700 ON/OFF Status display
14 Output status of dump selector solenoid SWV FOR HOIST 34800 ON/OFF Status display
15 Output current command value for dump EPC solenoid EPC HOIST DIR 34900 0 - 1020 mA
16 Output current detection value for dump EPC solenoid EPC HOIST 34901 0 - 1020 mA
17 Input status of overrun command OVERRUN SIG 35000 ON/OFF Status display
18 Input status of service brake oil pressure switch SERVICE BRAKE 35100 ON/OFF Status display
19 Input status of ignition switch terminal C KEY SW C 32300 ON/OFF Status display
ON/OFF, ON/
20 Input status of connector check (1 & 2) CONN CHK 1,2 30702 Status display
OFF
21 Front & rear differential slipping condition INT DIFF SLIDE 35200 SLIDE/NO Status display
22 Input status manual differential lock command INT M DIFF SIG 35300 ON/OFF Status display
23 Transmission output shaft F speed T/M SPEED:OUT 31401 0 - 65535 rpm
24 Transmission output shaft R speed T/M DIFF OUT 31402 0 - 65535 rpm
25 Front accumulator oil pressure ACC OIL PRE F 35500 0.00 - 50.26 MPa
26 Rear accumulator oil pressure ACC OIL PRE R 35501 0.00 - 50.26 MPa
CLOGGED/
27 Clogging status of brake filter BK OIL FILTER 35600 Status display
NORMAL
CLOGGED/
28 Clogging status of brake cooling filter RETARD FILTER 35700 Status display
NORMAL
CLOGGED/
29 Wear status of R.H. front brake DISK WEAR FR 35800 Status display
NORMAL
CLOGGED/
30 Wear status of L.H. front brake DISK WEAR FL 35801 Status display
NORMAL
CLOGGED/
31 Wear status of R.H. center brake DISK WEAR RFR 35802 Status display
NORMAL
CLOGGED/
32 Wear status of L.H. center brake DISK WEAR RFL 35803 Status display
NORMAL
CLOGGED/
33 Wear status of R.H. rear brake DISK WEAR RRR 35804 Status display
NORMAL
CLOGGED/
34 Wear status of L.H. rear brake DISK WEAR RRL 35805 Status display
NORMAL
Exhaust brake solenoid output (detection status & ON/OFF, (ON/
35 EXH BRAKE 35900 Status display
command status) OFF)
• ❄1. Used as the brake controller in E-SPEC.
20-96 1 HM400-1L
❄2. The lever is not installed in E-SPEC.
Note: The following monitoring items display data for 2 systems at the same time.
No. 6: Retarder lever input (displays 2 types at same time; does not display unit for conversion%)
No. 7: Retarder lever validation switch input status (displays 2 systems at same time)
No. 20: Connector check input status (displays 2 systems at same time)
No. 35: Exhaust brake solenoid output (displays 2 types at same time; output status displayed in ( )
1. Reduced Cylinder Mode (Cylinder Cut-out)

As one method of troubleshooting for the engine, the machine monitor
has a reduced cylinder function that can set the desired cylinder to the
NO INJECTION condition.
A. Starting engine
• With this function, it is possible to use the engine speed in
the reduced cylinder mode to judge if there is a problem
with any cylinder, so the engine can be used during the
operation.
B. Menu selection
i. Select the reduced cylinder mode on the menu screen of

Service mode 1 (Fig. 1).
ii.
With the menu selected, press the [ ] button and display
the cylinder selection screen (Fig. 2: example).
★ The cylinder No. and engine speed are display at the same
time.
C. Setting Cut-out Cylinder

• Operate each button and select the cylinder to be cut out (Fig.
3: example).
[>] button: Selector cursor moves to right
[<] button: Selector cursor moves to left
[ ] button: Cylinder is confirmed
[ ] button: Returns to menu screen
★ When the [ ] button is used to confirm the cut-out cylinder,
communication is carried out between the machine monitor
and engine controller. During this time, the cylinder No.
flashes. After completion of the communication, the segment
under the cylinder No. becomes black to show that the cylinder
has been cut out.
★ Single cylinders or multiple cylinders can be cut out.
HM400-1L 20-97 1
D. Canceling Cylinder Cut Out
• Cancel the cylinder cut out in the same way as when
setting the cut out (Fig. 4: example).
2. Adjustment Function (Tuning)

• Through the transmission controller, the machine monitor can
carry out the adjustment function to correct the difference in
operating feeling to a constant level caused by the individual
differences in the ECMV. It can also carry out the
self-adjusting learning function so that a constant gearshift
feeling is maintained in accordance with the wear of the
transmission clutch.
• When the following operations related to the power train have
Failure code Component name
been carried out, perform the adjustments.
• When the transmission has been overhauled or replaced DLF1KA Transmission input shaft
• When the transmission valve has been replaced DLF1LC speed sensor
• When the transmission controller has been replaced DLF2KA Transmission intermediate
• When an abnormality has occurred in the power train speed DLF2LC shaft speed sensor
sensor and it has been repaired (for details, see the failure DLF2KA Transmission output shaft
code in the chart on the right) DLF2LC R speed sensor
• When an abnormality has occurred in the transmission oil Transmission valve oil
DLF2KA
temperature sensor and it has been repaired (for details, see temperature sensor
the failure code in the chart on the right) DLF2LC Transmission oil filter
• When the transmission oil filter has become clogged and it
has been repaired (for details, see the failure code in the chart on the right)
For the adjustment operation, operate the machine monitor and machine
itself, and carry out the following items in order (Fig. 2).
★ ( ) indicates the menu to use for the adjustment operation.
(1) Adjusting individual difference of valve (02: ECMV TUNING
AUTO)
(2) Resetting gearshift feeling stabilized learning data (01: TM TRIG-
GER)
(3) Gearshift feeling stabilized initial learning (monitoring
function)
★ The MANUAL menu of [02: ECMV TUNING] is a special
function for the factory and is not used for service.
Preparatory work:
Adjusting ECMV oil temperature
★ It is necessary to carry out the adjustment operation at the specified
oil temperature, so check that there is no abnormality on the
machine and adjust the ECMV oil temperature as follows.
A. Start the engine.
20-98 1 HM400-1L
B. Display [ECMV oil temperature] with the machine data monitoring function. (Fig. 1).
C. TRANSMISSION No. 50
D. Raise ECMV oil temperature to 60 - 70fC by raising engine speed.
E. Keep engine speed in low idling for 3 minutes.
3. Adjustment Operation (1): Adjusting Individual Difference

Of Valve
★ See Preparatory work and check that the ECMV oil
temperature is at the specified temperature.
★ The adjustment operation is carried out automatically three
times for the Lo, Hi, R, 1st, 2nd, and 3rd valves.
A. Set the machine to the following conditions.

• Parking brake switch: ON
• AISS LOW switch: LOW
• Gearshift lever: N position
• Engine: Low idling
• Accelerator pedal: OFF (released)
B. Operate the machine monitor and display the adjustment menu

screen (Fig. 4).
• Adjustment menu: 02: ECMV TUNING AUTO
C. Check the condition of the machine again, press the [ ]

button, and start the adjustment operation (Fig. 5).
• [ ] button: Runs adjustment menu
★ The adjustment is carried out consecutively three times for the
applicable clutches and displays a screen like the one shown on the
right.
★ For each adjustment operation, the result is displayed as normal or
abnormal, so take action according to the display (Fig. 6).
No. Valve 1st time 2nd time 3rd time

1 Lo IP L-1 IP L-2 IP L-3
2 Hi IP H-1 IP H-2 IP H-3
3 R IP R-1 IP R-2 IP R-3
4 1st IP 1-1 IP 1-2 IP 1-3
5 2nd IP 2-1 IP 2-2 IP 2-3
6 3rd IP 3-1 IP 3-2 IP 3-3
★ If [3-3 OK] is displayed:
HM400-1L 20-99 1
• The adjustment operation has been completed correctly.
• (When the ignition switch is turned OFF, the adjusted value is
recorded in the controller.)
• If [NG 1] (Outside compensation condition) is displayed:
• Adjust the ECMV oil temperature correctly, check the set
conditions of the machine again, then repeat from Step 1).
• If [NG 2] (No fill) is displayed:
• Carry out troubleshooting for failure codes [15S[ ]MA]
[DDT[ ]KA], and if it is found to be normal, repeat from Step 1).
• If [NG 3] (Compensation value over] is displayed:
• Carry out troubleshooting for failure code [15S[ ]L1], and if it is
found to be normal, repeat from Step 1).
4. Adjustment Operation (2): Resetting Gearshift Feeling

Stabilized Learning Data
A. Operate the machine monitor and display the initial menu

screen (Fig. 7).
★ Initial menu: 01: TM TRIGGER
★ The present initial status is displayed on the bottom line of the
screen.
• Initializing completed: INITIAL STATUS
• Initializing not performed: TUNED
★ With the transmission adjustment, the learning data is initialized
from the following operation, regardless of the present initial status.
B. With the menu selected, press the [ ] button and display the
initial screen of the sub menu (Fig. 2).
• [ ] button: Runs initialize menu
C. Operate the buttons according to the screen display.

[ ] button: Run
• After carrying out initializing, check that INITIAL STATUS is
displayed on the bottom line of the screen.
5. Adjustment Operation (3): Initial Learning Of Gearshift Feel-

ing Stabilization
★ Check that the ECMV oil temperature is the specified
temperature. For details, see Preparatory work.
A. Carry out the adjustment operation in a place with ample room

for traveling and where the surrounding area is safe.
B. With the machine data monitoring function, display (R clutch

fill status] (Fig. 10).
• TRANSMISSION No. 37
20-100 1 HM400-1L
C. Run the engine at low idling, hold the gearshift lever at the N
position for 10 seconds, then operate the gearshift lever as
follows.
• Gearshift lever operation: N > R1 > N
D. Check the fill status with the monitoring display.

• If the display is [0], go on to the next step.
• If the display is [1], repeat Step 2) until it becomes [0].
E. Operate the gearshift lever to the D position, drive the machine, and shift up to F2 - F4.
• Shift up: F2 > F3 > F4
• Be careful not to shift up to F5. If the transmission shifts up to F5, start the procedure again and move the
machine off in F2.
F. After traveling for 10 seconds in F4, release the accelerator

pedal, and allow the machine to coast and shift down from F4
to F2.
• Shift down: F4 > F3 > F2
• Do not operate the brake while coasting.
G. Use the machine data monitoring function to display [Lo clutch

fill status] and [1st clutch fill status] and check the fill status
(Fig. 11).
• Lo clutch: TRANSMISSION No. 36
• Hi clutch: TRANSMISSION No. 38
• If the display is [0], the correction is complete.
• If the display is [1], repeat Steps 4) and 5) until it becomes [0].
6. Filter, Oil Replacement Time Setting Function

(MAINTENANCE MONITOR)
The machine monitor can set the maintenance interval for filters and oil,
which form the base for the filter and oil replacement time and display.
A. Menu selection
• Select Filter, oil replacement time setting function on the
menu screen of Service mode 1 (Fig. 1).
B. Selecting filter, oil replacement time setting item
i. With the menu selected, press the [ ] button and display

the initial screen of the set item (Fig. 2).
ii. [ ] button: Runs menu
iii. Press the [>] or [<] buttons to select the item to be set.
• [>] button: Goes on to next item
• [<] button: Goes back to last item
★ The set items are displayed endlessly in the internal set order (for details, see Table of filter and oil replacement time set
items).
C. If the maintenance items in the display for the filter and oil replacement time set items are selected, the following
content is displayed (Fig. 3).
1: Code (2 digits)
A: Filter and oil replacement time set items
2: Remaining time to set replacement time
HM400-1L 20-101 1
3: Number of times of replacement up to present
D. Changing replacement interval
i.With the set items selected, press the [ ] button and

display the interval input screen (Fig. 4: example).
[ ] button: Executes change function
★ The presently set interval is displayed on the screen.
ii.
Operate the buttons to input the interval (Fig. 4).
[ ] button: Returns to item selection screen
★ The time must always be input with four digits. For
numbers of less than four digits, input 0s at the beginning.
iii. When all the interval times are confirmed, the change
confirmation screen is displayed, so operate the buttons
according to the screen display (Fig. 5).
[ ] button: Run
Table Of Filter And Oil Replacement Time Set Items
No. Item Code Display Replacement time

1 Fuel filter 03 FUEL FILT 0500
2 Engine oil filter 02 ENG FILT 0500
3 Engine oil 01 ENG OIL 0500
4 Corrosion resistor 06 CORR RES 1000
5 Transmission oil 12 TM OIL 1000
6 Transmission oil filter 13 TM FILT 1000
7 Brake oil 17 BK OIL 1000
8 Brake oil filter 14 BK OIL FIL 1000
9 Brake cooling oil filter 16 BK C FIL 1000
10 Hydraulic filter 04 HYD FILT 2000
11 Differential case oil 11 DIFF OIL 2000
12 Final drive oil 08 FNL OIL 2000
13 Hydraulic oil 10 HYD OIL 4000
20-102 1 HM400-1L
1. Initialize Function (Initialize) (exclusive function for factory)
★ This is a special function for the factory and is not used for
service.
2. Procedure Of Switching The Service Mode To The Service

Mode 2
★ When replace the machine monitor to the new one, change
the data shown below to the data of the machine.
• Service meter data
• Odometer data
• Reverse travel odometer data
★ Never use this function except when replacing the
machine monitor to the new one.
★ Because it is necessary to mark the connectors behind the
machine monitor, when replacing the machine monitor,
carry out this procedure before installing the cover.
★ In case of using service mode 2, switch the display by
carrying out the procedure mentioned below.
A. Switching the service mode to the service mode 1.

Set the service mode to the service mode 1 by operating the
machine monitor.
• Switching the service mode to the service mode 2 is
possible only when the service mode is on the service
mode 1.
B. Operating the connectors and confirming the display.
i. Connect the OP7 connectors behind the machine monitor, and then disconnect them. (Fig. 1)
• After operating the OP7 connectors, keep them disconnected.
ii. After operating the connectors, confirm that the new initial display of service mode 2 is displayed. (Fig. 2)
• Initial display: Service meter setting function
C. Menu Selection
• Press the [>] or [<] buttons on the opening menu screen and the
menus of Service mode 2 are scrolled in the following order.
★ The menu is displayed in the places marked with [*].
[>] button: Goes on to next menu
[<] button: Goes back to previous menu
(1) Hourglass mark: Service meter setting function
(2) ODO: Function for setting value for total distance
traveled
(3) BACKWARD ODO: Function for setting value for total distance traveled in reverse
D. Completion Of Mode, Function

When operating at any point in any function, it is possible to finish the mode or function by using any of the follow-
ing methods.
i. When continuing operations in another mode or function:

Press the [ ] button and return to the mode screen to be used or menu screen to be used.
HM400-1L 20-103 1
★ Note that if the [ ] button is pressed on the YES/NO screen, the function will be executed.
★ If you return to the normal screen (operator mode) or service mode by mistake, repeat the procedure from Step 1)
above (there is no need to input the ID again).
ii. When completing all operations:

Turn the ignition switch OFF.
3. Service Meter Setting Function (Hourglass Mark)
A. Menu Selection
Select the setting function for the service meter on the menu
B. Setting service meter

the service meter input screen (Fig. 2).
ii.Operate each button and input the service meter times.

★ The time must always be input with five digits. For numbers of
less than five digits, input 0s at the beginning.
iii. When all the times are confirmed, the change confirmation
screen is displayed, so operate the buttons according to the
screen display (Fig. 3).
[ ] button: Run
4. Odometer Setting Function (ODO)
A. Menu Selection
Select the setting function for the distance traveled on the
menu screen of Service mode 2 (Fig. 1).
B. Setting Odometer Value

the odometer input screen (Fig. 2).
20-104 1 HM400-1L
ii.
Operate each button and input the odometer values.
★ The distance must always be input with five digits before the
decimal point and 1 digit after. For places where no numeral is
needed, input an 0.
iii. When all the times are confirmed, the change confirmation screen is displayed, so operate the buttons according
to the screen display (Fig. 3).
[ ] button: Run
5. Distance Traveled In Reverse Setting Function

(BACKWARD ODO)
A. Menu Selection
Select the setting function for the distance traveled in reverse
on the menu screen of Service mode 2 (Fig. 1).
B. Setting backward odometer value

the backward odometer input screen (Fig. 2).
ii.
Operate each button and input the values for the distance
traveled in reverse.
★ The distance must always be input with five digits before the
decimal point and 1 digit after. For places where no numeral is
needed, input an 0.
iii. When all the times are confirmed, the change confirmation screen is displayed, so operate the buttons according
to the screen display (Fig. 3).
[ ] button: Run
HM400-1L 20-105 1
12
MEMORANDUM
20-106 1 HM400-1L
TROUBLESHOOTING (GENERAL)
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-205
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-205
HANDLING ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS . . . . . . . . . . . . . 20-211
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-212
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . 20-215
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-216
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218
CONNECTOR TYPES AND MOUNTING LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-228
T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-252
CONNECTOR LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-255
HM400-1L 20-201 b
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! 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.
WARNING! 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.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. 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 hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
● Parts that have no connection with the failure or other unnecessary parts will be disassembled.
● It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F. Has the same kind of failure occurred before?
20-202 b HM400-1L
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
3. Check before troubleshooting.
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming the failure.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
B. The basic procedure for troubleshooting is as follows.
i. Start from the simple points.
ii. Start from the most likely points.
iii. Investigate other related parts or information.
6. Measures to remove root cause of failure.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
HM400-1L 20-203 b
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
20-204 b HM400-1L
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

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 hydraulic oil).
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT

1. Handling High Voltage Circuits
A. If the machine is equipped with an electronically controlled

engine, high voltage is used to control fuel injection,
(110 - 130 V) for the fuel injector drive. Never handle the
engine wiring harness while the engine is running, tamper with
or modify this circuit, sever injury may result due to the high
voltage and amps in the circuit. Always use caution when
working around this circuit.
2. Handling Wiring Harnesses And Connectors
A. Wiring harnesses consist of wiring connecting one component

to another component, connectors used for connecting and
disconnecting one wire from another wire, and protector or
tubes used for protecting the wiring. Compared with other
electrical components fitted 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.
3. Main Failures Occurring In Wiring Harness
A. Faulty contact of connectors:

(faulty contact between male and female). Problems with
faulty contact are likely to occur because the male connector is
not properly inserted into the female connector, or because one
or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidation of
the contact surfaces.
HM400-1L 20-205 b
B. Defective compression or soldering of connectors:
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.
C. Disconnections in wiring:
If the wiring is held and tugged 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
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
D. High pressure water entering a connector:

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector
depending on the direction of the water jet.
The connector is designed to prevent water from entering, but
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-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropriate action
before passing electricity through it.
E. Oil, grease or dirt stuck to connector:

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, and this will cause
a defective contact.If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or blow dry with air, and
spray it with a contact restorer.
★ When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
★ If there is water or oil present, it will increase the
contamination of the points, so clean with air until all
water and oil has been removed.
20-206 b HM400-1L
4. Removing, Installing, And Drying Connectors And Wiring
Harnesses.
A. Disconnecting connectors:
i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors
and not the wires. 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 connectors apart.
★ Never try to pull apart with one hand
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.
iii. When disconnecting male and female connectors, release

the lock and pull in parallel with both hands.
★ Never try to pull apart with one hand.
iv. Action to take after removing connectors.

After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
HM400-1L 20-207 b
B. Connecting connectors:
i. 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, faulty contact,
corrosion, or damage to the connector pins.
● Check that there is no damage or breakage to the
outside of the connector.
★ If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has gotten
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.
★ If there is any damage or breakage, replace the
connector.
ii. Assemble the connector securely.

Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.
iii. Correct any protrusion of the boot and any misalignment

of the wiring harness.
For connectors fitted with boots, correct any protrusion or
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct
position.
★ When blowing with dry air, there is danger that the oil
in the air may cause improper contact, so clean with
properly filtered air.
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
C. Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors have two
latches respectively, push them in until they click 2 times.
● Male connector (1), Female connector (2).
● Normal locking state (Horizontal): a, b, d
● Incomplete locking state (Diagonal): c
20-208 b HM400-1L
D. Drying wiring harness:
If there is any oil or dirt on the wiring harness, 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 follows:
i. Disconnect the connector and wipe off the water with a

dry cloth.
★ If the connector is blown dry with air, there is the risk
that oil in the air may cause a faulty contact, so avoid
blowing with air.
ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but be careful not
to make the connector or related parts too hot, as this
will cause deformation or damage to the connector.
iii. Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, spray it with
contact restorer and reassemble.
HM400-1L 20-209 b
HANDLING ELECTRONIC CONTROL UNIT

1. The electronic control unit contains a microcomputer and electronic
circuits.
★ This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control unit.
2. Do not open the cover of the control box unless necessary.
3. Do not place objects on top of the control unit.
4. Cover the control connectors with tape or a vinyl bag.
5. Do not leave the control unit in a place where it is exposed to rain.
6. Do not place the control unit on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.
7. Precautions when carrying out arc welding.

★ When carrying out arc welding on the body, disconnect all
wiring harness connectors connected to the control unit. Attach
the arc welding ground close to the welding point as possible.
20-210 b HM400-1L
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL

CIRCUITS
1. Always turn power OFF before disconnecting or connecting connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
5. When checking a single diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
6. When checking a dual diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
7. Always be aware of what you are measuring. Voltage, Ohms or

Amps. Always use caution when measuring a circuit.
★ When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are
measuring.
★ When measuring ohms, be sure the circuit is dead and has (no
voltage) in it before you take any readings. Be sure the meter is
set in the proper ohms range.
★ When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage your equipment or possibly cause
injury. Always study the operators manuel for the meter you
will be using.
HM400-1L 20-211 b
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 confirm 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 dust proof workshop, and the performance
should be confirmed with special test equipment.
3. Seal or cover all openings of disconnected piping.

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag,
this could cause particles or dirt to get into the system. Drain all oil
into a container and not unto the ground and be sure to follow the
proper environmental regulation for any disposal of oil.
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 cleaning
device is used, it is possible to filter out the dirt that has collected
during storage, so this is an even more effective method.
20-212 b HM400-1L
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. (Do not drain the oil from the hydraulic tank; but 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 equipment, 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 circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
HM400-1L 20-213 b
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Item Judgement Value Action
1. Check fuel level - Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel - Drain

3. Check oil level in hydraulic oil tank - Add oil
4. Check oil filter (Hydraulic, HST) - Replace
5. Check brake oil level - Add oil
6. Check engine oil level inside oil pan - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check play of steering wheel **See Testing & Adjustment Adjust
10. Check emergency steering - Repair
Air, Hydraulic, Mechanical equipment
11. Check tire inflation pressure and damage - Air charge or replace
Before Starting Checking Item
Tightening torque (See DISASSENBLY

12. Check loosen of hub nut AND ASSEMBLY) Tighten
13. Check effect of foot brake - Adjust

14. Check effect of parking brake - Adjust or repair
15. Check effect of emergency brake - Adjust or repair
16. Check operation of steering - Adjust or repair
17. Check direction of rear view mirror and under mirror - Adjust
18. Check effect of exhaust gas color and sound - Adjust or repair
19. Check effect retarder brake - Adjust or repair
20. Check effect body mounting rubber - Replace
21. Check sound of horn - Repair
22. Check flashing of lamps - Repair or replace
Electrical equipment
23. Check operation of gauge when during operation - Adjust or repair

24. Check operation of monitor panel - Adjust or repair
25. Check operation of machine monitor system - Adjust or repair
26. Check for missing central warning lamps - Repair or replace
27. Check for looseness, corrosion of battery terminal, wiring - Tighten or clean
28. Check for looseness, corrosion of alternator terminal, wiring - Tighten or clean
29. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or clean
30. Check for abnormal noise, smell - Repair
31. Check for oil leakage - Repair
32. Carry out air bleeding - Bleed air
33. Check battery voltage (Engine stopped) 24 V Charge or replace
Others Checking Item
34. Check battery electrolyte level - Add

35. Check for discolored, burnt, exposed wiring - Replace
36. Check for missing wiring clamps, hanging wire - Repair
37. Check for water leakage on wiring (Pay particular attention to water
leaking on connectors or terminals) - Dry
38. Check for blown, corroded fuses - Replace

After running for several minutes: 28.5 -
39. Check alternator voltage (Engine running at 1/2 throttle or above) 29.5V Replace
40. Check sound of actuation of battery relay (When starting switch is - Replace
turned ON, OFF)
20-214 b HM400-1L
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS

1. Categories of troubleshooting codes
★ If the machine monitor displays a failure code, the name of the controller is also displayed at the same time, so the
troubleshooting codes are categorized according to the name of each controller. (This may also includes some failure
codes for the electrical system that are not displayed)
★ Failures of the hydraulic and mechanical system that the machine monitor cannot display are categorized as H mode.
Troubleshooting Code Troubleshooting system
ENG Troubleshooting of engine controller system
TM Troubleshooting of transmission controller system
BK Troubleshooting of retarder controller system
MON Troubleshooting of machine monitor system
H Troubleshooting of hydraulic, mechanical system
2. Procedure for troubleshooting

★ If a problem occurs on the machine, or if any problem is felt, carry out troubleshooting as follows.
A. When failure code is displayed on machine monitor.

If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the content of the
display, then go to the applicable troubleshooting for the failure code.
B. If no failure code is displayed on the machine monitor but the failure is recorded in memory.
If it is impossible to check the failure code display on the machine monitor when a problem occurs, use the trouble-
shooting history display function in the service mode of the machine monitor to check if there is a failure code.
If a failure code is recorded, it is probable that it is the cause, so go to the applicable troubleshooting for the failure
code.
C. If no failure code is displayed and no failure history is recorded.

If it is impossible to check the failure display on the machine monitor when a problem occurs, and there is also no
failure code recorded in the troubleshooting history display function in the service mode of the machine monitor, it is
probable that are problem has occurred in the hydraulic or mechanical system or in the electrical system that the con-
troller cannot detect.
In such a case, check the condition of the failure carefully, then go to the applicable troubleshooting for the failure.
HM400-1L 20-215 b
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS

★ This method is also displayed at the beginning of each electrical system troubleshooting mode. It is important to follow
each step in the troubleshooting chart. Do not skip steps, jump ahead or stop when a problem is found. It is important to
complete all steps due to the fact that there may be several other problems causing the failure code. The chart is set-up to
start with the most likely problem first down to the least likely.
• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.
Tools and Procedures
• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.
Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings
1. Sensor or Actuator
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)
Your
Test procedure for component only. readings 1
information
Resistance Ω
A. What you are testing
or Voltage Your
information
2. Diode Test
• With ignition switch in the “OFF” position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm
electrical flow. Electrical flow should be one way only. (See section 20-111 for detail).
At a diode, between point (x) and (x) Continuity one

A. Diode test Resistance Ω 3 Yes or No
reverse meter lead polarity each time to check diode. way only?
3. Wiring Harness Assembly Test

Your
Test procedure for harness. (connector) to (connector) readings 4
A. Open or high Resistance Ω information
resistance or Voltage
Your
information
Your
B. Short to chassis Test procedure for harness. (connector) to (connector) readings 6
information
Resistance Ω
ground or within
or Voltage
harness Your
information
4. Additional Components To Be Tested

Resistance Ω Your
A. What you are testing Test procedure for any additional components. readings 8
or Voltage information
20-216 b HM400-1L
Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
● Connector No.: Indicates (Type - numbers of a pin) (color)

● Arrow: Roughly indicates the location in the machine where it is installed.
Chart Use
★ Repair Shop Use
● When using this chart in a repair shop environment where you have access to a copier it is advised to remove the
pages of the fault codes displayed on the machine monitor and copy these pages. After copping the needed pages,
return the original pages back to the Shop Manual for future use. On the copied pages in the right hand column of the
chart you can record your findings for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
★ Road Service Use
● When using this chart while on a road service call where a copier is not available it is advised to use a blank piece of
paper and number it from #1 through the last number listed in conjunction with the Shop Manual. Record your
readings by each number on the paper for final analysis. Do not write on the original chart in the Shop Manual and
complete all test procedures.
Chart Tips
● Check all fuses and fuse links first.

● If the system has a relay replace the relay with a known good relay, do not test the relay itself.
● For diode checking procedures see “POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL
CIRCUITS” page 111
● When checking Ohms in a system or component always isolate the component you are checking, this will ensure there are
no additional circuits adding continuity to the component you are testing.
● Never measure Amps unless instructed in the testing procedure. Damage to the meter or injury may result.
● Never use a welder or a battery system of a higher voltage than the machine you are troubleshooting to jump or supply
electricity to. Damage to the machines electrical system may result.
HM400-1L 20-217 b
12
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS
Like the electrical diagnostic procedures it is important to complete all steps requires in the testing procedures. This method is
broken down into three steps: Question the operator, Checks before troubleshooting and Using the cross-reference tables.
Below is a description od each step.
1. Question The Operator
The questions to ask the operator are given below the failure symptom.
If the answers to the questions match the information given, follow the
arrow to reach the probable cause of the failure. Consider the contents
of the question and consult the table while proceeding to step 2 and 3 to
grasp the true cause
2. Checks Before Troubleshooting
Before starting the trouble shooting procedures or measuring any

pressures, first check the listed basic items under (Checks Before
Troubleshooting) these checks may avoid any wasted time on
unnecessary troubleshooting. The items given under this procedure are
the items which must be considered particular for that symptom before
starting troubleshooting.
3. Using The Cross-reference Table
A. Operate the machine to check the symptom. If it is not

necessary to follow the troubleshooting checks in order; follow
an order which is easiest to carry out troubleshooting.
B. Find the appropriate cause from the cause column. If the

symptom appears, the ❍ marks on that line indicate the
possible causes. (For item No. 2 in the table on the right, the
possible causes are c or e). If there is only one ❍: Carry out the
troubleshooting items (where the same cause is marked with
❍), Check if the symptom appears, then repair. If there are two
❍: Go to Step C) to narrow down the possible causes.
20-218 b HM400-1L
12
C. Operate the machine and check the troubleshooting items other
than in 1). Operate the machine and check the items in the
same way as in 1), and if the symptom appears, record that
item for further reference. (In the chart on the right, the symp-
tom appears again for item 5).
D. Find the appropriate chart for the cause from the cause column.
In the same way as in step 2), if the symptom appears, the ❍
marks on that line indicate the possible causes. (For items No.
5 in the table on the right, the possible causes are b or e).
E. Narrow down the possible causes. There is one column causes

among the causes located in Steps B) and D). (One cause
marked ❍ appears on the line for both items.) This cause is
comment to both the symptoms in troubleshooting Steps 1) and
3). The causes which are not comment to both troubleshooting
items (items which are not marked ❍ for both symptoms) are
unlikely causes, so it is advised to ignore them. (In the example
given on the right, the causes for troubleshooting Item 2) are c
or e, and the cause for troubleshooting Item 5) are b or e, so
cause e is comment to both)
F. Repeat the operations in Steps C) and D) and E) until one cause

(one comment cause) remains. If the cause cannot be
narrowed down to one cause, narrow the causes down to a pos-
sible cause.
G. Remedy: If the causes are narrowed down to one comment

cause, take action given in the remedy column. The symbols
given in the remedy column indicate the following:
X: Replace ∆ : Repair A: Adjust C: Clean
HM400-1L 20-219 b
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
12
CONNECTOR TYPES AND MOUNTING LOCATIONS
Connector No. Type No. of pins Name of component 3-dimensional drawing display
1-PS DT2 2 Transmission 1st clutch solenoid 4/4
1-SW DT2 2 Transmission 1st clutch fill switch 4/4
2-PS DT2 2 Transmission 2nd clutch solenoid 4/4
2-SW DT2 2 Transmission 2nd clutch fill switch 4/4
3-PS DT2 2 Transmission 3rd clutch solenoid 4/4
3-SW DT2 2 Transmission 3rd clutch fill switch 4/4
A1 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
A2 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
AC1 1-pin connector 1 Air conditioner unit 2/4 (Overall drawing: Left)
ACBM KES 2 Air conditioner blower motor 2/4 (Overall drawing: Right)
ACM1 AMP 5 Air conditioner temperature adjustment servo motor 2/4 (Overall drawing: Right)
ACM2 AMP 5 Air conditioner vent mode selector servo motor 2/4 (Overall drawing: Left)
ACM3 AMP 5 Air conditioner FRESH/RECIRC selector servo motor 2/4 (Overall drawing: Right)
ACP1 AMP 16 Air conditioner control panel 2/4 (Overall drawing: Left)
ACP2 AMP 12 Air conditioner control panel 2/4 (Overall drawing: Left)
ACPS SUMITOMO 2 Air conditioner pressure switch 2/4 (Overall drawing: Right)
ACR1 AMP 4 Air conditioner blower main relay 2/4 (Overall drawing: Right)
ACR2 AMP 4 Air conditioner blower Hi relay 2/4 (Overall drawing: Right)
ACR3 AMP 4 Air conditioner blower M2 relay 2/4 (Overall drawing: Right)
ACR4 AMP 4 Air conditioner blower M1 relay 2/4 (Overall drawing: Right)
ACR5 AMP 4 Air conditioner compressor clutch relay 2/4 (Overall drawing: Right)
ACRD DT2 2 Air conditioner gas pressure switch 1/4 (Overall drawing: Left)
ACRE AMP 4 Air conditioner blower resistor 2/4 (Overall drawing: Right)
ACTH KES 2 Air conditioner thermistor 2/4 (Overall drawing: Right)
AISS M 6 AISS LOW switch 2/4 (Overall drawing: Left)
AS1 SWP 6 Accelerator pedal 2/4 (Overall drawing: Left)
AS2 SWP 3 Accelerator pedal 2/4 (Overall drawing: Left)
ASS DT2 2 Air suspension seat 2/4 (Overall drawing: Right)
ATC1 MIC 17 Transmission controller 2/4 (Overall drawing: Right)
ATC2 MIC 21 Transmission controller 2/4 (Overall drawing: Right)
ATC3A 040 20 Transmission controller 2/4 (Overall drawing: Right)
ATC3B 040 16 Transmission controller 2/4 (Overall drawing: Right)
ATC4 040 12 Transmission controller 2/4 (Overall drawing: Right)
ATC5A 040 20 Transmission controller 2/4 (Overall drawing: Right)
ATC5B 040 16 Transmission controller 2/4 (Overall drawing: Right)
ATC6 X 4 Software rewrite connector (transmission controller) 2/4 (Overall drawing: Right)
B1 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
B2 M 1 Emergency cancel connector 2/4 (Overall drawing: Right)
B01 DT2 2 Front brake (left) wear switch 1/4 (Overall drawing: Left)
B02 DT2 2 Center brake (left) wear switch 1/4 (Overall drawing: Right)
B03 DT2 2 Brake cooling filter clogging switch 1/4 (Overall drawing: Left)
B04 DT2 2 Brake filter clogging switch 1/4 (Overall drawing: Left)
B05 DT2 2 Rear brake (left) wear switch 1/4 (Overall drawing: Right)
B08 DT2 2 Rear brake (right) wear switch 1/4 (Overall drawing: Right)
B09 DT2 2 Intermediate connector 1/4 (Overall drawing: Left)
B14 DT2 2 Parking brake solenoid valve 1/4 (Overall drawing: Left)
B15 DT2 2 Foot brake oil pressure switch 1/4 (Overall drawing: Left)
20-220 b HM400-1L
B16 DT2 2 Rear brake oil pressure switch 1/4 (Overall drawing: Right)
B17 DT2 2 Parking brake oil pressure switch 1/4 (Overall drawing: Left)
B18 DT2 2 Rear brake EPC valve 1/4 (Overall drawing: Left)
B19 DT2 2 Front brake EPC valve 1/4 (Overall drawing: Left)
B20 DT2 2 Rear accumulator oil pressure switch 1/4 (Overall drawing: Left)
B21 DT2 2 Front accumulator oil pressure switch 1/4 (Overall drawing: Left)
B22 DT2 2 Rear accumulator gas pressure sensor -
B23 DT2 2 Front accumulator gas pressure sensor -
B24 DT2 3 Rear accumulator oil pressure sensor 1/4 (Overall drawing: Left)
B25 DT2 3 Front accumulator oil pressure sensor 1/4 (Overall drawing: Left)
B26 DT2 2 Center brake (right) wear switch 1/4 (Overall drawing: Right)
B27 DT2 3 Steering angle sensor 1/4 (Overall drawing: Right)
B28 DT2 2 Front brake (right) wear switch 1/4 (Overall drawing: Left)
B29 DT2 2 Exhaust brake solenoid valve -
B30 DT2 2 Exhaust brake oil pressure switch -
B31 DT2 3 Dump pilot valve (selector solenoid) 1/4 (Overall drawing: Right)
B32 DT2 2 Dump pilot valve (EPC solenoid) 1/4 (Overall drawing: Right)
B34 DT2 3 Body positioner sensor 1/4 (Overall drawing: Right)
B35 DT2 2 Front differential lock solenoid valve 1/4 (Overall drawing: Left)
B36 DT2 2 Differential lock motor solenoid valve 1/4 (Overall drawing: Right)
B39 DT2 2 Front differential lock oil pressure switch 1/4 (Overall drawing: Left)
B40 DT2 2 Rear differential lock oil pressure switch 1/4 (Overall drawing: Right)
BL47 M 2 Back-up lamp 1/4 (Overall drawing: Right)
BL48 M 2 Back-up lamp 1/4 (Overall drawing: Right)
BLS M 6 Rotating lamp switch 2/4 (Detail drawing: X)
BRC1 MIC 17 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC2 MIC 21 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC3A 040 20 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC3B 040 16 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC4 040 12 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC5A 040 20 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC5B 040 16 Retarder controller (❄) 2/4 (Overall drawing: Right)
BRC6 X 4 Software rewrite connector (retarder) 2/4 (Overall drawing: Right)
BT1 - - Fuse box 2/4 (Overall drawing: Right)
BT2B - - Fuse box 2/4 (Overall drawing: Right)
BZ2 M 2 Buzzer 2/4 (Overall drawing: Left)
CAB1 DT2 8 Intermediate connector 2/4 (Overall drawing: Left)
CAB2 DT2 8 Intermediate connector 2/4 (Overall drawing: Left)
CAN1 DT2 3 Resistor 2/4 (Overall drawing: Left)
CAN2 DT2 3 Resistor 2/4 (Overall drawing: Left)
CG1 1-pin connector 1 Cigarette lighter 2/4 (Overall drawing: Left)
CG2 1-pin connector 1 Cigarette lighter 2/4 (Overall drawing: Left)
CH1 S 8 Machine monitor mode selector switch 1 2/4(Detail drawing: X)
CH2 S 8 Machine monitor mode selector switch 2 2/4 (Detail drawing: X)
CJA DT2 8 Joint connector 1/4 (Overall drawing: Left)
❄1.Used as the retarder controller in E-SPEC.
HM400-1L 20-221 b
12
CJAA DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJB DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJC DT2 8 Joint connector 1/4 (Overall drawing: Right)
CJD DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJF DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJG DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJH DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJJ DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJK DT2 8 Joint connector 1/4 (Overall drawing: Right)
CJL DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJM DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJN DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJP DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJR DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJS DT2 8 Joint connector 1/4 (Overall drawing: Left)
CJT DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJU DT2 6 Joint connector 1/4 (Overall drawing: Left)
CJX DT1 6 Joint connector 1/4 (Overall drawing: Left)
CJY DT1 8 Joint connector 1/4 (Overall drawing: Left)
CJZ DT2 6 Joint connector 1/4 (Overall drawing: Right)
CK1 YAZAKI 6 Machine monitor check switch 2/4 (Detail drawing: X)
CM DT2 8 Combination switch 2/4 (Overall drawing: Left)
CM DT2 2 Intermediate connector 1/4 (Overall drawing: Left)
CN1 070 12 Engine controller 2/4 (Overall drawing: Right)
CN1 DT2 2 No. 1 cylinder injector 3/4
CNS1 DT2 12 Intermediate connector 2/4 (Overall drawing: Right)
COM 1-pin connector 1 Air conditioner unit 2/4 (Overall drawing: Left)
COMP DT2 2 Air conditioner compressor 1/4 (Overall drawing: Left)
D/L-PS DT2 2 Inter-axle differential lock clutch solenoid 4/4
D/L-SW DT2 2 Inter-axle differential lock clutch fill switch 4/4
D01 DT2 2 Diode 2/4 (Overall drawing: Right)
D04 DT2 2 Diode 2/4 (Overall drawing: Left)
20-222 b HM400-1L
12
DEF M 6 Inter-axle differential lock switch 2/4 (Overall drawing: Left)
DEL M 6 Left and right differential lock switch 2/4 (Overall drawing: Left)
DFS DT2 3 Left and right differential lock pedal 2/4 (Overall drawing: Right)
DIO DT2 2 Diode 1/4 (Overall drawing: Left)
DL DT2 12 Intermediate connector 2/4 (Overall drawing: Right)
DPC1 070 20 Machine monitor 2/4 (Overall drawing: Left)
DPC2A 070 18 Machine monitor 2/4 (Overall drawing: Left)
DPC2B 070 12 Machine monitor 2/4 (Overall drawing: Left)
DPC3A 070 18 Machine monitor 2/4 (Overall drawing: Left)
DPC7 X 4 Software rewrite connector (machine monitor) 2/4 (Overall drawing: Left)
DSL 1-pin connector 1 Left door switch
DSR 1-pin connector 1 Right door switch 1/4 (Overall drawing: Left)
DT1 DT2 3 Intermediate connector 1/4 (Overall drawing: Left)
DT4 DT2 12 Intermediate connector 1/4 (Overall drawing: Right)
E Terminal - Ground 1/4 (Overall drawing: Left)
E02 DT2 2 Steering oil pressure switch 1/4 (Overall drawing: Left)
E1 Terminal - Emergency steering motor 1 -
E2 Terminal - Emergency steering motor 2 -
EG1 DT2 12 Intermediate connector 2/4 (Overall drawing: Left)
EG4 HD30 31 Intermediate connector 1/4 (Overall drawing: Left)
EG5 HD30 31 Intermediate connector 1/4 (Overall drawing: Left)
ER Terminal - Ground 1/4 (Overall drawing: Left)
ER Terminal - Ground 1/4 (Overall drawing: Right)
ER1 Terminal - Ground 2/4 (Overall drawing: Left)
ER1 - - Ground
ER2 Terminal - Ground 2/4 (Detail drawing: V)
ER3 Terminal - Ground
ER3 Terminal - Ground 2/4 (Overall drawing: Left)
EREV DT2 2 Engine speed sensor 3/4
HM400-1L 20-223 b
12
EXH M 6 Exhaust brake switch 2/4 (Overall drawing: Left)
FE1 DT2 2 Transmission output shaft (F) speed sensor 1/4 (Overall drawing: Left)
FLB 1-pin connector - Turn signal lamp flasher 2/4 (Overall drawing: Left)
FLL 1-pin connector - Turn signal lamp flasher 2/4 (Overall drawing: Left)
FOG M 6 Fog lamp switch 2/4 (Detail drawing: X)
FS3 1-pin connector 1 Spare power source connector -
FWL M 2 Left front working lamp 1/4 (Overall drawing: Left)
FWM 2 Front window washer motor 1/4 (Overall drawing: Left)
FWR M 2 Right front working lamp 1/4 (Overall drawing: Left)
G DT1 2 Engine G speed sensor 3/4
G2 Terminal - Ground 1/4 (Overall drawing: Left)
G21 Terminal - Air conditioner ground 2/4 (Overall drawing: Right)
GND Terminal - Battery ground 1/4 (Overall drawing: Left)
H1 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
H2 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
H10 1-pin connector 1 Heater unit 2/4 (Overall drawing: Left)
H20 1-pin connector 1 Heater unit 2/4 (Overall drawing: Left)
HAZ M 6 Hazard switch 2/4 (Overall drawing: Left)
HN 1-pin connector - Horn switch 2/4 (Overall drawing: Left)
H-PS DT2 2 Transmission Hi clutch solenoid 4/4
HSL DT2 4 Dump lever (potentiometer) 2/4 (Overall drawing: Right)
H-SW DT2 2 Transmission Hi clutch fill switch 4/4
JCA DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCB DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCC DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCD DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCE DT2 8 Joint connector
JCF DT2 8 Joint connector 2/4 (Overall drawing: Right)
JCG DT2 8 Joint connector 2/4 (Overall drawing: Right)
JO1 HD30 9 Intermediate connector 1/4 (Detail drawing: Y)
JO12 DT2 12 Joint connector 1/4 (Overall drawing: Right)
JO13 DT2 12 Joint connector 1/4 (Overall drawing: Right)
JO14 HD30 31 Joint connector 1/4 (Overall drawing: Right)
JO15 HD30 31 Joint connector 1/4 (Overall drawing: Right)
JO18 HD30 14 Intermediate connector 1/4 (Overall drawing: Left)
JO19 HD30 9 Intermediate connector 1/4 (Overall drawing: Left)
20-224 b HM400-1L
12
KAI 1-pin connector 1 Rotating lamp 1/4 (Detail drawing: Z)
L/U-PS DT2 2 Torque converter lock-up clutch solenoid 4/4
L/U-SW DT2 2 Torque converter lock-up clutch fill switch 4/4
LK0 DT2 2 Dump lever (solenoid) 2/4 (Overall drawing: Right)
L-PS DT2 2 Transmission Lo clutch solenoid 4/4
LS M 3 Rheostat (resistor for dimming panel lighting) 2/4 (Detail drawing: X)
L-SW DT2 2 Transmission Lo clutch fill switch 4/4
LUB-T DT2 2 Transmission oil temperature sensor 4/4
M1 Terminal - Emergency steering motor 1 -
M2 Terminal - Emergency steering motor 2 -
MC1 M 1 Memory clear connector 2/4 (Overall drawing: Right)
MC2 M 1 Memory clear connector 2/4 (Overall drawing: Right)
MON1 1-pin connector 1 Rear view monitor 2/4 (Overall drawing: Left)
MS M 4 Model selection connector (engine controller) 2/4 (Overall drawing: Right)
MS11 M 1 Model selection connector (transmission controller) 2/4 (Overall drawing: Right)
N1 DT2 2 Transmission input shaft speed sensor 4/4
N2 DT2 2 Transmission intermediate shaft speed sensor 4/4
N3 DT2 2 Transmission output shaft (R) speed sensor 4/4
NE DT1 2 Engine Ne speed sensor 3/4
OF Terminal - Engine oil filter clogging switch 3/4
OL DT1 1 Engine oil level sensor 3/4
OP1 M 1 Machine monitor setting connector 2/4 (Detail drawing: W)
OPS DT2 2 Seat heater 2/4 (Overall drawing: Right)
P01 M 3 Left head lamp 1/4 (Overall drawing: Left)
P02 1-pin connector - Left front combination lamp 1/4 (Overall drawing: Left)
P05 DT2 2 Left turn signal lamp 1/4 (Overall drawing: Left)
P06 DT2 2 Right turn signal lamp 1/4 (Overall drawing: Left)
P07 X 2 Left fog lamp 1/4 (Overall drawing: Left)
P13 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
HM400-1L 20-225 b
12
P14 1-pin connector 1 Horn 1/4 (Overall drawing: Left)
P20 M 6 Right rear combination lamp 1/4 (Overall drawing: Right)
P21 M 6 Left rear combination lamp 1/4 (Overall drawing: Right)
P22 1-pin connector - Intermediate connector 1/4 (Overall drawing: Left)
P29 1-pin connector - Right front combination lamp 1/4 (Overall drawing: Left)
P32 M 3 Right head lamp 1/4 (Overall drawing: Left)
P33 X 2 Right fog lamp 1/4 (Overall drawing: Left)
PCV1 DENSO 2 Fuel supply pump PCV1 3/4
PCV2 DENSO 2 Fuel supply pump PCV2 3/4
PFUEL DENSO 3 Engine common rail pressure sensor 3/4
PIM DENSO 3 Engine boost pressure sensor 3/4
PSH Terminal - Engine oil high-pressure sensor 3/4
PSL Terminal - Engine oil low-pressure sensor 3/4
PWL 1-pin connector 1 Left power window motor 1/4 (Detail drawing: Z)
PWM M 6 Power mode switch 2/4 (Overall drawing: Left)
PWR 1-pin connector 1 Right power window motor 1/4 (Detail drawing: Z)
R01 Relay 5 Engine drive relay 2/4 (Detail drawing: V)
R02 Relay 5 Transmission neutral relay 2/4 (Detail drawing: V)
R03 Relay 5 Parking brake relay 2/4 (Detail drawing: V)
R04 Relay 6 Brake lamp relay 2/4 (Detail drawing: V)
R05 Relay 6 Back-up lamp, buzzer relay 2/4 (Detail drawing: V)
R06 Relayr 6 Fog lamp relay 2/4 (Detail drawing: V)
R07 Relay 6 Front working lamp relay 2/4 (Detail drawing: V)
R08 Relay 6 Rear working lamp relay 2/4 (Detail drawing: V)
R11 Relay 5 Horn relay 2/4 (Detail drawing: V)
R14 Relay 5 Breaker cut relay 2/4 (Detail drawing: V)
R15 Relay 5 Transmission cut relay 2/4 (Detail drawing: V)
R16 Relay 6 Hazard relay 1 2/4 (Detail drawing: V)
R17 Relay 5 Hazard relay 2 2/4 (Detail drawing: V)
R19 Relay 5 Parking brake safety relay 2/4 (Detail drawing: V)
R21 Relay 6 Side lamp relay 2/4 (Detail drawing: V)
R22 Relay 5 Rotating lamp relay 2/4 (Detail drawing: V)
R25 Relay 5 Right power window down relay 2/4 (Detail drawing: V)
R26 Relay 5 Right power window up relay 2/4 (Detail drawing: V)
R27 Relay 5 Left power window down relay 2/4 (Detail drawing: V)
R28 Relay 5 Left power window up relay 2/4 (Detail drawing: V)
R29 Relay 6 Head lamp Hi relay 2/4 (Detail drawing: V)
R30 Relay 5 Head lamp Lo relay 2/4 (Detail drawing: V)
R31 S 10 Passing relay 2/4 (Overall drawing: Left)
R32 Relay 5 Dust indicator relay 2/4 (Detail drawing: V)
R33 M 6 Parking brake switch 2/4 (Overall drawing: Left)
R34 - 7 Left power window switch 2/4 (Overall drawing: Right)
R35 - 7 Right power window switch 2/4 (Overall drawing: Right)
R36 Relay 5 Engine power relay 2/4 (Detail drawing: V)
R37 Relay 5 Auto preheat relay 2/4 (Detail drawing: V)
20-226 b HM400-1L
12
RAD YAZAKI 9 Radio 2/4 (Overall drawing: Left)
RDC YAZAKI 9 Cassette stereo 2/4 (Overall drawing: Left)
RE1 KES 2 Resistor 2/4 (Overall drawing: Right)
RL M 1 Room lamp 1/4 (Overall drawing: Left)
RL2 1-pin connector 1 Room lamp 2 1/4 (Overall drawing: Left)
R-PS DT2 2 Transmission R clutch solenoid 4/4
R-SW DT2 2 Transmission R clutch fill switch 4/4
RTL DT2 6 Retarder lever 2/4 (Overall drawing: Left)
RWL 1-pin connector 2 Left rear working lamp 1/4 (Overall drawing: Left)
RWM 2 Rear window washer motor 1/4 (Overall drawing: Left)
RWR 1-pin connector 2 Right rear working lamp 1/4 (Overall drawing: Left)
SBS DT2 2 Seat belt switch 2/4 (Overall drawing: Right)
SDE M 6 Side lamp switch 2/4 (Detail drawing: X)
SF1 DT2 12 Gearshift lever 2/4 (Overall drawing: Left)
SF2 DT2 2 Gearshift lever 2/4 (Overall drawing: Left)
SLL M 2 Left side lamp 1/4 (Overall drawing: Right)
SLR M 2 Right side lamp 1/4 (Overall drawing: Left)
S-NET - 5 S-NET monitoring connector 2/4 (Overall drawing: Right)
SP5 1-pin connector 1 Right speaker 1/4 (Overall drawing: Left)
SP6 1-pin connector 1 Right speaker 1/4 (Overall drawing: Left)
SP7 1-pin connector 1 Left speaker 1/4 (Overall drawing: Left)
SP8 1-pin connector 1 Left speaker 1/4 (Overall drawing: Left)
T01 DT2 2 Radiator water level switch 1/4 (Overall drawing: Left)
T03 DT2 2 Transmission filter clogging switch 1/4 (Overall drawing: Left)
T04 DT2 2 Steering oil temperature switch 1/4 (Overall drawing: Right)
T05 DT2 2 Hydraulic oil filter clogging switch 1/4 (Overall drawing: Right)
T06 DT2 2 Hydraulic oil level switch 1/4 (Overall drawing: Right)
T08 DT2 2 Fuel level sensor 1/4 (Overall drawing: Left)
T10 DT2 3 Inclination sensor 1/4 (Overall drawing: Right)
T11 DT2 - Air cleaner clogging sensor 1/4 (Overall drawing: Left)
T13 DT2 2 Rear retarder oil temperature sensor 1/4 (Overall drawing: Right)
T14 DT2 2 Center retarder oil temperature sensor 1/4 (Overall drawing: Right)
T15 DT2 2 Front brake oil temperature sensor 1/4 (Overall drawing: Left)
TC-INT DT2 3 Torque converter oil pressure sensor 4/4
TC-SE DT2 2 Torque converter oil temperature sensor 4/4
TEL DT2 12 Intermediate connector 2/4 (Overall drawing: Left)
TG 1-pin connector 1 Tachograph 1/4(Detail drawing: Z)
TG2 1-pin connector 1 Tachograph 1/4(Detail drawing: Z)
THL DT1 2 Fuel temperature sensor 3/4
TMF M 1 Intermediate connector 2/4 (Overall drawing: Right)
TMO M 1 Intermediate connector 2/4 (Overall drawing: Right)
TWH DT2 2 Engine water high-temperature sensor 3/4
TWL DT2 2 Engine water low-temperature sensor 3/4
WFM M 6 Front wiper motor 2/4 (Overall drawing: Left)
WFR Relay 6 Front wiper relay 2/4 (Overall drawing: Left)
WM M 4 Intermediate connector 1/4 (Overall drawing: Left)
WPS DT2 12 Wiper switch 2/4 (Overall drawing: Left)
WRF M 6 Front working lamp switch 2/4 (Detail drawing: X)
WRM M 4 Rear wiper motor 1/4 (Overall drawing: Left)
WRR M 6 Rear working lamp switch 2/4 (Detail drawing: X)
HM400-1L 20-227 b
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
★ Deuscht connector has marks of pin numbers on the wiring harness side.
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— —
• Grommet: red • Grommet: red
20-228 b HM400-1L
SWP Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
HM400-1L 20-229 b
SWP Type Connector

Number of
Number
16 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-230 b HM400-1L
M Type Connector
Number of
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
HM400-1L 20-231 b
8 799-601-7340
20-232 b HM400-1L
S Type Connector
Number of
Number
8 799-601-7140
10 (white) 799-601-7150
12 (white) 799-601-7350
16 (white) 799-601-7330
HM400-1L 20-233 b
S Type Connector
Number of
Number
10 (blue) —
— —
12 (blue) 799-601-7160
16 (blue) 799-601-7170
20-234 b HM400-1L
MIC Type Connector

Number of
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
11 (Quantity: 5 pieces) (Quantity: 5 pieces) —
5 799-601-2710

9 799-601-2950

13 799-601-2720

HM400-1L 20-235 b
MIC Type Connector

Number of
Number
17 799-601-2730

21 799-601-2740

— —
20-236 b HM400-1L
AMP040 Type Connector

Number of
Number
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
12 799-601-7190
— Housing part number: 79A-222-3440

16 799-601-7210
Housing part number: 79A-222-3450

—
20 799-601-7220
— Housing part number: 79A-222-3460

★ Terminal part number: 79A-222-3470 (for all numbers of pins).
HM400-1L 20-237 b
AMP070 Type Connector

Number of
Number
10 799-601-7510
— Part number: 08195-10210
12 799-601-7520
— Part number: 08195-12210
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
20-238 b HM400-1L
20 799-601-7550
— Part number: 08195-20210
L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
2 —
— —
PA Type Connector
Number of
Number
9 —
— —
HM400-1L 20-239 b
BENDIX (MS) Type Connector

Number of
Number
10 799-601-3460
— —
20-240 b HM400-1L
KES1 Automobile Type Connector

Number of
Number
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
HM400-1L 20-241 b
KES1 Automobile Type Connector

Number of
Number
8 —
08027-10820 (Black) 08027-10870 (Black)
20-242 b HM400-1L
Connector for relay (Socket)

Number of
Number
5 799-601-7360
— —
6 799-601-7370
— —
Type F Type Connector

(shell size T-adapter Part
code) Pin (Male terminal) Body (Female terminal)
Number
4 —
— —
HM400-1L 20-243 b
★ The pin No. is also marked on the connector (electric wire insertion end)
Type HD30 Series connector

code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
20-244 b HM400-1L

Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
HM400-1L 20-245 b

Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
20-246 b HM400-1L

Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
HM400-1L 20-247 b

Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
20-248 b HM400-1L
DT Series connector
Number
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
HM400-1L 20-249 b
DT Series connector
Number
Number
8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
20-250 b HM400-1L
DTM Series connector
Number of
Pins T-adapter Part
Number
2 799-601-9010
DTHD Series connector

Number
Number
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
HM400-1L 20-251 b
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker
assemblies are shown in the lines.
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
—
Port No. Connector type Pin No.
799-601-2600 For measuring box Econo-21P O O O O O O

799-601-3100 For measuring box MS-37P O
799-601-3200 For measuring box MS-37P O
799-601-3300 For measuring box Econo-24P O
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P O O
799-601-3420 BENDIX(MS) 24P O O
799-601-3430 BENDIX(MS) 17P O O
799-601-3440 BENDIX(MS) 17P O O
799-601-3450 BENDIX(MS) 5P O O
799-601-3460 BENDIX(MS) 10P O O
799-601-3510 BENDIX(MS) 5P O O
799-601-3520 BENDIX(MS) 14P O O
799-601-3530 BENDIX(MS) 19P O O
799-601-2910 BENDIX(MS) 14P O O
799-601-3470 CASE O
799-601-2710 MIC 5P O O O O
799-601-2720 MIC 13P O O O O
799-601-2730 MIC 17P O O O O O O O
799-601-2740 MIC 21P O O O O O O O
799-601-2950 MIC 9P O O O O
799-601-2750 ECONO 2P O O
799-601-2760 ECONO 3P O O
799-601-2770 ECONO 4P O O
799-601-2780 ECONO 8P O O
799-601-2790 ECONO 12P O O
799-601-2810 DLI 8P O O
799-601-2820 DLI 12P O O
799-601-2830 DLI 16P O O
799-601-2840 Extension cable O O O
799-601-2850 CASE O
799-601-7010 X 1P O O
799-601-7020 X 2P O O O O
799-601-7030 X 3P O O O O
799-601-7040 X 4P O O O O
799-601-7050 SWP 6P O O O
799-601-7060 SWP 8P O O O
799-601-7310 SWP 12P O
20-252 b HM400-1L
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
—
799-601-7070 SWP 14P O O

799-601-7320 SWP 16P O
799-601-7080 M 1P O O
799-601-7090 M 2P O O O O
799-601-7110 M 3P O O O O
799-601-7120 M 4P O O O O
799-601-7130 M 6P O O O O
799-601-7340 M 8P O
799-601-7140 S 8P O O O O
799-601-7150 S 10P-White O O O O
799-601-7160 S 12P-Blue O O O
799-601-7170 S 16P-Blue O O O O
799-601-7330 S 16P-White O
799-601-7350 S 12P-White O
799-601-7180 AMP040 8P O
799-601-7190 AMP040 12P O O
799-601-7210 AMP040 16P O O O O
799-601-7220 AMP040 20P O O O O
799-601-7230 Short connector X-2 O O O O
799-601-7240 Case O O
799-601-7270 Case O
799-601-7510 070 10P O
799-601-7520 070 12P O
799-601-7530 070 14P O
799-601-7540 070 18P O
799-601-7550 070 20P O
799-601-7360 Relay connector 5P O
799-601-7370 Relay connector 6P O
799-601-7380 JFC connector 2P O
799-601-9010 DTM 2P O O
799-601-9020 DT 2P O O
799-601-9030 DT 3P O O
799-601-9040 DT 4P O O
799-601-9050 DT 6P O O
799-601-9060 DT 8P-Gray O O
799-601-9070 DT 8P-Black O O
799-601-9080 DT 8P-Green O O
799-601-9090 DT 8P-Blown O O
799-601-9110 DT 12P-Gray O O
799-601-9120 DT 12P-Black O O
799-601-9130 DT 12P-Green O O
799-601-9140 DT 12P-Blown O O
799-601-9210 HD30 18-8 O O
799-601-9220 HD30 18-14 O O
HM400-1L 20-253 b
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
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
—
799-601-9230 HD30 18-20 O O

799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 2-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 For measuring box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
799-601-9420 For boost pressure, fuel 3P O
799-601-9430 PVC socket 2P O
20-254 b HM400-1L
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
12
CONNECTOR LAYOUT DRAWING
HM400-1L 20-255 b
20-256 b HM400-1L
12
HM400-1L 20-257 b
12
20-258 b HM400-1L
12
HM400-1L 20-259 b
12
20-260 b HM400-1L
TROUBLESHOOTING OF ENGINE CONTROL
SYSTEM (ENG MODE)
CONNECTOR ARRANGEMENT AND LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-303

ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-309
CONTENT OF CODE DISPLAY (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-324
(ENG-1) FAILURE CODE [A000N1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
ENGINE OVERSPEEDS (N1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-326
(ENG-2) FAILURE CODE [A570NX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-327
ENGINE OIL FILTER CLOG SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-327
(ENG-3) FAILURE CODE [AD00L2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
COMMON RAIL HIGHER THAN SET VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-328
(ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-329
COMMON RAIL PRESSURE HIGH OR LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-329
(ENG-6) FAILURE CODE [AD10MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-331
(ENG-7) FAILURE CODE [AD10MB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-331
(ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-332
(ENG-10 OR 11) FAILURE CODE [AD51KA] or [AD51KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-334
(ENG-12) FAILURE CODE [ADA1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-335
OPEN IN NO. 1 INJECTOR SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-335
(ENG-13) FAILURE CODE [ADZKKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-337
SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-337
(ENG-14) FAILURE CODE [ADB1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-340
(ENG-15) FAILURE CODE [ADC1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-342
(ENG-16) FAILURE CODE [ADD1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-344
(ENG-17) FAILURE CODE [ADDZKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-346
(ENG-18) FAILURE CODE [ADE1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-349
(ENG-19) FAILURE CODE [ADF1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-351
(ENG-20) FAILURE CODE [B@BAZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-353
ENGINE OIL PRESSURE DROP (ZG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-353
(ENG-21) FAILURE CODE [B@BAZK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-355
ENGINE OIL LEVEL DROP (ZK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-355
(ENG-22) FAILURE CODE [B@BCNS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-356
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS) . . . . . . . . . . . . . . . . . . . . 20-356
(ENG-23) FAILURE CODE [D181KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-358
HM400-1L 20-301 1
(ENG-24) FAILURE CODE [D182KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-360
(ENG-25) FAILURE CODE [D1D0KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-362
(ENG-26) FAILURE CODE [D5ZAKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
(ENG-27) FAILURE CODE [DB20KT] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
(ENG-28) FAILURE CODE [DB22KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
DROP IN VOLTAGE LOAD POWER SUPPLY (KK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
(ENG-29) FAILURE CODE [DB29KQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE CONTROLLER WIRING
HARNESS (KQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
(ENG-30) FAILURE CODE [DB2AMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-371
“Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA) . . . . . . . . . . . . . . . . 20-371
(ENG-31) FAILURE CODE [KK11KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
TROUBLE IN INPUT OF ignition switch C (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
(ENG-32) FAILURE CODE [DDA1L5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-373
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5) . . . . . . . . . . . . . . . . . . . . . . . 20-373
(ENG-33) FAILURE CODE [DDE2L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-375
ENGINE OIL PRESSURE DROP (L6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-375
(ENG-34) FAILURE CODE [DGE2KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-377
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . 20-377
(ENG-35) FAILURE CODE [DGE3LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6) . . . . . . . . . . . . . . . . . . . . . . . . . 20-378
(ENG-36) FAILURE CODE [DGE4KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-379
(ENG-37) FAILURE CODE [DH30KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
(ENG-38) FAILURE CODE [DH40KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . 20-382
(ENG-39) FAILURE CODE [DK10KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX) . . . . . . . . . . . . . . . . . . . . . . 20-384
(ENG-40) FAILURE CODE [DLE3LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-386
(ENG-41) FAILURE CODE [DLE1LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-387
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-387
(ENG-42) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
ENGINE DOES NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-388
20-302 1 HM400-1L
TROUBLESHOOTING CONNECTOR ARRANGEMENT AND LOCATIONS
CONNECTOR ARRANGEMENT AND LOCATIONS
HM400-1L 20-303 1
20-304 1 HM400-1L
HM400-1L 20-305 1
20-306 1 HM400-1L
HM400-1L 20-307 1
20-308 1 HM400-1L
TROUBLESHOOTING ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-309 1
20-310 1 HM400-1L
12
HM400-1L 20-311 1
TROUBLESHOOTING CONTENT OF CODE DISPLAY
12
CONTENT OF CODE DISPLAY
Failure
Location Of Failure Nature Of Failure Probable Cause
Code
A000N1 Engine: Over speed (N1) ENG-1 C. Engine speed went above
(ENG-1) operating range
A570NX Engine oil filter: Clogged (NX) Signal circuit of engine oil filter clog- • Clogged engine oil filter (when
(ENG-2) ging switch became open (shut off system is working normally)
from GND) while engine was running • Defective engine oil filter clogging
switch
• Open in switch signal circuit wiring
harness
• Defective engine controller
AD00L2 Common rail: * See Contents (L2) Common rail fuel pressure has risen • Viscosity of fuel is too high
(ENG-3) to high pressure (level 1) (unsuitable fuel)
• Defective overflow valve
• Clogged overflow piping
• Defective pressure limiter
• Defective common rail fuel
pressure sensor
AD00MA Common rail: Function impossible Common rail fuel pressure has risen • Same as failure code [AD00L2]
(ENG-4) (MA) to high pressure (level 2)
AD10L3 Fuel supply pump: * See Contents Non-force feed (level 1) has occurred • Defective fuel low-pressure circuit
(ENG-5) (L3) in fuel supply pump (etc.)
• Defective fuel supply pump PCV
• Defective pressure limiter
• Defective common rail fuel
pressure sensor
• Defective fuel injector
• Leakage from high-pressure fuel
piping
AD10MA Fuel supply pump: Function impossi- Abnormal pressure has occurred in • Same as failure code [AD00L2]
(ENG-6) ble (MA) common rail fuel pressure
AD10MB Fuel supply pump: Drop in function Non-force feed (level 2) has occurred • Same as failure code [AD10L3]
(ENG-7) (MB) in fuel supply pump
AD11KA Fuel supply pump solenoid valve 1: Open has occurred in PCV1 circuit of • Defective fuel supply pump PCV1
(ENG-8) Open (KA) fuel supply pump • Open in PCV1 (+) circuit wiring
harness
• Open or short circuit with chassis
ground in PCV1 (-) circuit wiring
harness
AD11KB Fuel supply pump solenoid valve 1: Excessive current has flowed in • Defective fuel supply pump PCV1
(ENG-9) Short circuit (KB) PCV1 circuit of fuel supply pump • Short circuit with chassis ground or
short circuit with power source in
PCV1 (+) circuit wiring harness
• Short circuit with power source in
PCV1 (-) circuit wiring harness
20-312 1 HM400-1L
Problem That Appears On Action

Condition When Normal Action By Controller
Machine Code
• Stops fuel injection until engine Engine speed varies abnormally E02
speed goes to operating range
A. Sensor resistance value • Carries out operation under • If machine continues to be used as E01
of terminal normal control it is, there is danger that dirt will
• When normal: Max. 1 W circulate inside engine
• When clogged: Min. 1 MW
• Carries out operation with limited • Engine output is reduced E03

output
• Carries out operation with limited • Engine output and speed are E03
output and engine speed reduced
• Carries out operation with limited • Engine output is reduced E03
output
• Carries out operation under • Engine output is reduced E03

normal control
• Carries out operation with limited • Engine output and speed are E03
output and engine speed reduced
• Solenoid resistance value • Turns output to PCV1 OFF • No great effect on machine E03
PCV1 (male) (1) - (2): 2.3 - 5.3 W (however, if failure code
[AD51KA] occurs at the same
time, the engine stops)
PCV1 (male) (1) - (2): 2.3 - 5.3 W (however, if failure code [AD51KB]
occurs at the same time, the
engine stops)
HM400-1L 20-313 1
12
Failure
Code
AD51KA Fuel supply pump solenoid valve 2: An open has occurred in the PCV2 • Defective fuel supply pump PCV2
(ENG-10) Open (KA) circuit of the fuel supply pump • Open in PCV2 (+) circuit wiring
harness
ground in PCV2 (-) circuit wiring
harness
AD51KB Fuel supply pump solenoid valve 2: Excessive current has flowed in • Defective fuel supply pump PCV2
(ENG-11) Short circuit (KB) PCV2 circuit of fuel supply pump • Short circuit with chassis ground or
PCV2 (+) circuit wiring harness
PCV1 (-) circuit wiring harness
ADA1KA No. 1 injector solenoid valve: Open An open has occurred in No. 1 injec- • Defective No. 1 injector solenoid
(ENG-12) (KA) tor solenoid circuit • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (-) circuit wiring
harness
ADZKKB No. 1, 2, 3 injector solenoid valve: Excessive current has flowed in No. • Defective No. 1 injector solenoid
(ENG-13) Short circuit (KB) 1 injector solenoid circuit, No. 2 injec- • Defective No. 2 injector solenoid
tor solenoid circuit, or No. 3 injector • Defective No. 3 injector solenoid
solenoid circuit • Short circuit with chassis ground or
No. 1 solenoid (+) circuit and
(-) circuit wiring harness
• Short circuit with chassis ground or
ADB1KA No. 2 injector solenoid valve: Open Open has occurred in No. 2 injector • Defective No. 2 injector solenoid
(ENG-14) (KA) solenoid circuit • Open in solenoid (+) circuit wiring
harness
harness
ADC1KA No. 3 injector solenoid valve: Open Open has occurred in No. 3 injector • Defective No. 3 injector solenoid
harness
harness
ADD1KA No. 4 injector solenoid valve: Open Open has occurred in No. 4 injector • Defective No. 4 injector solenoid
harness
harness
20-314 1 HM400-1L

Machine Code
PCV2 (male) (1) - (2): 2.3 - 5.3 Ω (however, if failure code [AD11KA]
engine stops)
PCV2 (male) (1) - (2): 2.3 - 5.3 Ω (however, if failure code [AD11KB]
engine stops)
• Solenoid resistance value • Turns output to No. 1 injector • Engine output is reduced E03
CN1 (male) (1) - (2): 0.4 - 1.1 Ω solenoid OFF
• Solenoid resistance value • Turns output to No. 1 injector • Engine output is greatly reduced E03
CN2 (male) (1) - (2): 0.4 - 1.1 Ω • Turns output to No. 2 injector
• Turns output to No. 3 injector
solenoid OFF
HM400-1L 20-315 1
Failure
Code
ADDZKB No. 4, 5, 6 injector solenoid valve: Excessive current has flowed in No. • Defective No. 4 injector solenoid
(ENG-17) Short circuit (KB) 4 injector solenoid circuit, No. 5 injec- • Defective No. 5 injector solenoid
tor solenoid circuit, or No. 6 injector • Defective No. 6 injector solenoid
solenoid circuit • Short circuit with chassis ground or
ADE1KA No. 5 injector solenoid valve: Open Open has occurred in No. 5 injector • Defective No. 5 injector solenoid
harness
harness
ADF1KA No. 6 injector solenoid valve: Open Open has occurred in No. 6 injector • Defective No. 6 injector solenoid
harness
harness
B@BAZG Engine oil: Drop in oil pressure (ZG) When running at low idling, signal cir- • Drop in oil pressure (when system
(ENG-20) cuit of engine oil pressure low-pres- is working normally)
sure switch became closed • Defective engine oil low-pressure
(connected to GND), or when engine switch
speed was more than 1300 rpm, sig- • Defective engine oil high-pressure
nal circuit of oil pressure high-pres-
switch
sure switch became closed
(connected to GND) • Short circuit with chassis ground in
low or high -pressure switch signal
circuit wiring harness
B@BAZK Engine oil: Drop in level (ZK) Signal circuit of engine oil pressure • Drop in engine oil level (when
(ENG-21) switch became open (shut off from system is working normally)
GND) • Defective engine oil level switch
• Open in switch circuit wiring
harness
B@BCNS Radiator coolant: Overheat (NS) Engine coolant temperature went • Engine coolant temperature
(ENG-22) above operating range overheats (when system is
working normally)
D181KZ Preheating relay contact: Open or Open, short circuit with ground, or • Defective heater relay
(ENG-23) short circuit (KZ) short circuit with power source has • Defective preheater relay
occurred in signal circuit of heater • Open, short circuit with chassis
relay ground, or short circuit with power
source in relay signal circuit wiring
harness
20-316 1 HM400-1L

Machine Code
• Solenoid resistance value • Turns output to No. 4 injector • Engine output is greatly reduced E03
CN4 (male) (1) - (2): 0.4 - 1.1W solenoid OFF
CN5 (male) (1) - (2): 0.4 - 1.1W • Turns output to No. 5 injector
CN6 (male) (1) - (2): 0.4 - 1.1W solenoid OFF
• Turns output to No. 6 injector
solenoid OFF
CN5 (male) (1) - (2): 0.4 - 1.1 W solenoid OFF
CN6 (male) (1) - (2): 0.4 - 1.1 W solenoid OFF
• Low-pressure switch resistance • Carries out operation under • If the machine continues to be E03
value PSL - ground normal control used as it is, the engine may seize
• When engine is stopped: up
Max. 1W
• When engine speed is 600 rpm or
more: Min. 1 MW
PSH - ground
• When engine is stopped:
Max. 1W
• When engine speed is 1300 rpm or
more: Min. 1 MW
• Switch resistance value • Carries out operation under • If the machine continues to be E01
OL (male) (1) - ground normal control used as it is, the engine may seize
• When oil level is normal: Max. 1 W up
• When oil level is low: Min. 1 MW
• Limits fuel injection until • Engine output is reduced E02

temperature goes down to
operating range
• Preheating input signal voltage • Carries out operation under • It is difficult to start the engine in E03
CN4 (3) - ground normal control low temperatures
• When preheating is stopped: Max.
1V
• When preheating is being used: 20
- 30 V
HM400-1L 20-317 1
Failure Location Of Failure Nature Of Failure Probable Cause

Code
D182KZ Preheating relay coil: Open or Open or short circuit with ground • Defective preheater relay
(ENG-24) short circuit (KZ) has occurred in drive circuit of • Open or short circuit with chassis ground in
preheater relay relay power source circuit wiring harness
• Open or short circuit with chassis ground in
relay drive circuit wiring harness
D1DDKB Engine controller load power Voltage was generated in power • Defective engine power source relay
(ENG-25) source relay: Short circuit (KB) supply circuit of controller when • Short circuit with power source circuit wiring
ignition switch was OFF harness
D5ZAKX Engine throttle modify 1 signal: Voltage in throttle modify signal • Defective transmission controller
(ENG-26) Input signal outside range (KX) circuit went ou ts ide n ormal • Open or short circuit with chassis ground in
range (6 - 15 V) signal circuit wiring harness
DB20KT Engine controller: Abnormality Abnormality has occurred inside • Open in GND circuit wiring harness
(ENG-27) inside controller (KT) controller • Defective engine controlle
DB22KK Engine controller load power Voltage in controller power sup- • Defective engine power source relay
(ENG-28) source relay: Drop in power ply voltage circuit dropped when • Open or short circuit with chassis ground in
source voltage (KT) ignition switch was ON relay (1) circuit wiring harness
relay (2) circuit wiring harness
DB29KQ Engine controller connecting wir- Model selection signal does not • Defective model selection connector
(ENG-29) ing harness: Model selection sig- match setting inside controller • Open in signal 1 circuit wiring harness
nal mismatch (KQ) • Open in signal 2 circuit wiring harness
• Open in signal 3 circuit wiring harness
• Open in GND circuit wiring harness
DB2AMA Engine controller fuel injection Fuel injection quantity control set • Defective setting of fuel injection quantity
(ENG-30) quantity control switch: Function switch inside controller is not set control setting switch
impossible (MA) at correct position • Defective engine controller
KK11KB Ignition switch: Short circuit (KB) Terminal C signal from ignition • Defective ignition switch
(ENG-31) switch came ON when engine • Short circuit with power source in signal
was running circuit wiring harness
DDA1L5 Acceleration switch: * See Con- Idling validation switch of accel- • Defective accelerator pedal
(ENG-32) tents (L5) erator pedal does not match • Open, short circuit with chassis ground, or
throttle angle signal short circuit with power source in switch
signal 2 wiring harness
• Open, short circuit with chassis ground, or
short circuit with power source in switch
signal 3 wiring harness
• Open in switch GND circuit wiring harness
20-318 1 HM400-1L

Condition When Normal Action By Controller Machine Code
• Relay resistance value • Cannot turn preheater relay ON • It is difficult to start the engine in E03
R37 (male) (1) - (2): 100 - 500W low temperatures
• Power source voltage • Carries out operation under nor- • No great effect on machine E01
CN7 (6) (14) - (5) (13) mal control
Ignition switch is OFF: Max. 1 V
Ignition switch is ON: 20 - 30 V
• Signal voltage • Does not modify throttle • There is shock when shifting E01
CN4 (16) - ground: 6 - 15 V transmission
• Carries out operation under • If the machine continues to be E03

normal control used as it is, the engine may seize
up
• Engine stops during operation
• Engine cannot be started
• Power source voltage • Engine stops during operation E03
CN7 (6)(14) - (5)(13) • Engine cannot be started
When ignition switch is OFF: Max.
1V
When ignition switch is ON:
20 - 30 V
• Signal voltage • Uses model with default setting to • Does not give specified engine E03
CN4 (13) - ground: Max. 1 V carry out control output
CN4 (14) - ground: 20 - 30 V
CN4 (15) - ground: Max. 1 V
• Carries out operation under • Fuel injection quantity control E01

normal control setting cannot be changed
• Signal voltage • Carries out operation under • Operates normally 10 seconds E03
CN4 (2) - ground normal control after starting
When Ignition switch is ON:
Max. 1 V
When Ignition switch is at START:
20 - 30 V
• CN4 (11) - ground (signal 2) • Carries out operation under • No great effect on machine E01
Throttle voltage normal control
•When less than 0.446 V: Max. 1 V
• When more than 0.446 V: 15 - 30 V
• CN4 (12) - ground (signal 3)
Throttle voltage
•When less than 0.446 V: 20 - 30 V
•When more than 0.446 V: Max. 1 V
HM400-1L 20-319 1

Code
DDE2L6 Engine oil pressure switch: * Engine oil pressure switch signal • Defective engine oil low-pressure switch
(ENG-33) See Contents (L6) does not match condition of • Defective engine oil high-pressure switch
engine • Open or short circuit with chassis ground in
low-pressure switch signal circuit wiring
harness
• Open in high-pressure switch signal circuit
wiring harness
DGE2KX Engine coolant temperature sen- Signal from engine coolant high- • Defective engine coolant high-temperature
(ENG-34) sor (for high temperature): Input temperature sensor is outside sensor
signal outside range (KX) normal range • Open or short circuit with chassis ground in
sensor signal circuit wiring harness
DGE3LC Failure code [DGE3LC] (Engine Engine coolant temperature sen- • Defective engine coolant low-temperature
(ENG-35) coolant temperature sensor sor (for low temperature): * See sensor
(low-temperature): * See Con- Contents (L6) • Open or short circuit with chassis ground in
tents (L6))
DGE4KX Fuel temperature sensor: Input Signal from fuel temperature • Defective fuel temperature sensor
(ENG-36) signal outside range (KX) sensor is outside normal range • Open or short circuit with chassis ground in
• Open in sensor GND circuit wiring harness
DH30KX Boost pressure sensor: Input Signal from boost sensor is out- • Defective boost pressure sensor
(ENG-37) signal outside range (KX) side normal range • Open or short circuit with chassis ground in
sensor power source circuit wiring harness
sensor GND circuit wiring harness
DH40KX Common rail pressure sensor: Signal from common rail fuel • Defective common rail fuel pressure sensor
(ENG-38) Input signal outside range (KX) pressure sensor is outside nor- • Open or short circuit with chassis ground in
mal range sensor power source circuit wiring harness
DK10KX Throttle angle sensor: Input sig- Throttle angle signal from accel- • Defective accelerator pedal
(ENG-39) nal outside range (KX) erator pedal is outside normal • Open or short circuit with chassis ground in
range sensor power source circuit wiring harness
20-320 1 HM400-1L
12
Action
Condition When Normal Action By Controller Problem That Appears On Machine
Code
• Low-pressure switch resistance • Carries out operation under • If the machine continues to be E01
value PSL - ground normal control used as it is, the engine may seize
• With engine stopped: 1 Ω up
• Engine speed is 600 rpm or
more: Min. 1 MΩ
• High-pressure switch resistance
value PSH - ground
• When engine is stopped:
Max. 1Ω
• When engine speed is 1300
rpm or more: Min. 1 MΩ
• Sensor resistance value • Carries out operation under nor- • Coolant temperature display on E01
(coolant temperature: 10 - 100°C) mal control machine monitor is not correct
• TWH (male) (1) - (2): 90 - 3.5 kΩ • Fixes coolant temperature signal
output to machine monitor to 90°C
• Sensor resistance value • Carries out operation under • Exhaust gas color in low E01
(coolant temperature: 10 - 100°C) normal control temperatures is poor
• TWL (male) (1) - (2): 9 - 0.3 kΩ • It is difficult to start the engine in
low temperatures
• Sensor resistance value (fuel • Carries out operation under • Output drops slightly in low E01
temperature: 10 - 100°C)THL normal control temperatures
(male) (1) - (2): 9 - 0.3 kΩ
• Sensor power source voltage Carries out operation under normal • No great effect on machine E03
PIM (1) - (3): 4.6 - 5.4 V control
• Sensor signal voltage
PIM (2) - (3): 0.3 - 4.7 V
• Sensor power source voltage • Limits output with open control • Engine output is reduced E03
PFUEL (1) - (3): 4.6 - 5.4 V
PFUEL (2) - (3): 0.3 - 4.7 V
• Sensor power source voltage • Controls at low idling or high idling • Engine speed is fixed at low idling E03
AS1 (3) - (1): 4.6 - 5.4 V according to signal from idling or high idling, it is impossible to
• Sensor signal voltage validation switch control acceleration at medium
AS1 (2) - (1): 0.3 - 4.5 V range
HM400-1L 20-321 1
12
Failure
Code
DLE3LC Engine Ne speed sensor: * See Con- Signal from engine Ne speed sensor • Defective engine Ne speed sensor
(ENG-40) tents (LC) does not match signal from engine G • Open or short circuit with chassis
speed sensor ground in sensor signal circuit
wiring harness
ground in sensor GND circuit
wiring harness
DLE1LC Engine G speed sensor: * See Con- Signal from engine G speed sensor • Defective engine G speed sensor
(ENG-41) tents (LC) does not match signal from engine • Open or short circuit with chassis
Ne speed sensor ground in sensor signal circuit
wiring harness
ground in sensor GND circuit
wiring harness
20-322 1 HM400-1L
12

Machine Code
• Sensor resistance value • Carries out operation with limited • Engine output is reduced E03
• NE (male) (1) - (2): 85 - 210W output
• Sensor resistance value • Carries out operation with limited • Engine output is reduced E03
• G (male) (1) - (2): 1.4 - 3.5 kW output
Failure phenomena of L Series problem codes (L*)
Problem code Nature of problem (phenomenon, nature of problem that occurs)

L6 Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature
HM400-1L 20-323 1
TROUBLESHOOTING INFORMATION CONTAINED IN TESTING PROCEDURES
INFORMATION CONTAINED IN TESTING PROCEDURES

★ The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to
isolate each part of the circuit.
• Failure.

Your
Resistance Ω information
or Voltage
Your
information
2. Diode Test


Your
information
A. Open or high Resistance Ω
Your
information
Your
B. Short to chassis information
Resistance Ω
ground or within
or Voltage Your
harness
information

Resistance Ω Your
20-324 1 HM400-1L

HM400-1L 20-325 1
TROUBLESHOOTING (ENG-1) FAILURE CODE [A000N1]
(ENG-1) FAILURE CODE [A000N1]
ENGINE OVERSPEEDS (N1)

Controller
Action Code Error Code
Code Trouble Engine overruns (N1)
E02 A000N1 ENG-1
Description of • Engine speed exceeded operating range.
Trouble
Controller • Stops fuel injection until engine speed lowers to operating range.
Reaction
Effect on Machine • Engine speed fluctuates abnormally.
Related Informa- • Engine speed can be checked with monitoring function (Code: 01004).
tion
Causes Standard Value in Normal State and Remarks on Troubleshooting
1) Turn ignition switch ON.
2) Operate machine monitor.
1 —
Perform troubleshooting for
Another code is displayed, too.
displayed code.
Diagnostic
When machine is so used that engine Remove cause and repair damaged
procedures for 2 Overrun of engine will overrun. parts of engine.
error code
1) Start engine.
3 Defective engine controller Engine speed can be read normally. Defective engine controller.
Engine speed cannot be read Perform troubleshooting for error
normally. codes [DEL3LG] and [DEH1LC].
20-326 1 HM400-1L
TROUBLESHOOTING (ENG-2) FAILURE CODE [A570NX]
12
(ENG-2) FAILURE CODE [A570NX]
ENGINE OIL FILTER CLOG SENSOR SYSTEM

• Trouble in engine oil filter sensor system.
Contents Of Trouble • ENG code 2 displayed.
• Engine oil filter clog warning is on.

Steps Circuit Diagnostic Procedures For Error Code [A570NX] Specifications No. Readings
Engine Oil Filter — Install a new oil filter and change engine oil Failure code? 1 Yes or No
1. Engine Oil Filter Clog Sensor Unit

• With ignition switch in the "OFF" position.
• Disconnect (EG5) connector from filter sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
• Start engine and run engine at a low idle.
A. Sensor test Resistance Ω At sensor EG5, between (23) and chassis ground. (OL) open 2

• Disconnect (EG5) connector from filter clog sensor.
• Disconnect (CN6) connector from engine controller and install T-adapter on (CN6) wiring harness connector only.
A. Open or high
Resistance Ω Between connectors EG5, (23) and CN6, (5) 0.0 to 1.0Ω 3
resistance
B. Short to chassis
ground or within Resistance Ω At connector EG5, between (23) and chassis ground. (OL) open 4
harness
3. Engine Controller Unit

• No testing procedure for the controller.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine Controller Unit.
Be sure all steps are completed correctly before faulting the controller unit.
Related circuit diagram
HM400-1L 20-327 1
TROUBLESHOOTING (ENG-3) FAILURE CODE [AD00L2]
(ENG-3) FAILURE CODE [AD00L2]
COMMON RAIL HIGHER THAN SET VALUE

Controller
Code Trouble Common rail higher than set value
E03 AD00L2 ENG-3, 4
Description of • Common rail fuel pressure rose (Level 1).
Trouble
Controller • Operates with limited output.
Reaction
Effect on Machine • Engine output lowers.
• The common rail pressure can be checked with monitoring function (Code: 36400).
Related • The converted torque can be checked with monitoring function (Code: 36700).
Information
• Engine speed can be checked with monitoring function (Code: 01004).

1 Defect concerned to another error code
Another code is displayed, too. displayed code.
Proper fuel for atmospheric Fuel use is proper.
temperature is used.
2 Use of improper fuel
Proper fuel for atmospheric Fuel used is improper (replace).
temperature is not used.
Defective mechanical system of common 1) Loosen overflow valve joint of fuel supply pump.
rail fuel pressure sensor, clogging of over- 2) Operate priming pump.
flow piping, defective overflow valve,
3 defective pressure limiter, Fuel leaks out. Go to 5.
defective electrical system of common rail
fuel pressure sensor Fuel does not leak out. Go to 4.
1) Disassemble overflow valve of fuel supply pump.
2) Check inside of overflow valve.
Diagnostic 4 Defective overflow valve
procedures for error Spring or seat is broken or ball is stuck. Defective overflow valve.
code Spring and seat are normal and ball is
not stuck. Overflow valve is normal.
1) Perform this after performing 3.

Defective mechanical system of common 2) Loosen joint of common rail pressure limiter.
rail fuel pressure sensor, clogging of over- 3) Start engine.
5 flow piping, defective pressure
limiter, defective electrical system of com- Fuel leaks out. Go to 6.
mon rail fuel pressure sensor
Fuel does not leak out. Go to 7.
2) Perform troubleshooting for error code [DH40KX].
Defective pressure limiter, defective elec-
6 trical system of common rail fuel pressure There is trouble in electrical system. Trouble in electrical system of
sensor common rail fuel pressure sensor.
There is not trouble in electrical sys-
Trouble in pressure limiter.
tem.
Overflow piping is clogged. Clogging in overflow piping.
7 Clogging of overflow piping Trouble in mechanical system of
Overflow piping is not clogged.
common rail fuel pressure sensor.
20-328 1 HM400-1L
TROUBLESHOOTING (ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3]
(ENG-4 OR 5) FAILURE CODE [AD00MA] OR [AD10L3]
COMMON RAIL PRESSURE HIGH OR LOW

Controller
Code Trouble Common rail out of set value
E03 AD00L2 ENG-3, 4
Description of • Common rail fuel pressure rose (Level 1).
Trouble
Controller • Operates with limited output.
Reaction
Effect on Machine • Engine output lowers.
• The common rail pressure can be checked with monitoring function (Code: 36400).
Related • The converted torque can be checked with monitoring function (Code: 36700).
Information
• Engine speed can be checked with monitoring function (Code: 01004).

1 Defect concerned to another error code
Another code is displayed, too. displayed code.
Proper fuel for atmospheric Fuel use is proper.
temperature is used.
2 Use of improper fuel
Proper fuel for atmospheric Fuel used is improper (replace).
temperature is not used.
Defective mechanical system of common 1) Loosen overflow valve joint of fuel supply pump.
rail fuel pressure sensor, clogging of over- 2) Operate priming pump.
flow piping, defective overflow valve,
3 defective pressure limiter, Fuel leaks out. Go to 5.
defective electrical system of common rail
fuel pressure sensor Fuel does not leak out. Go to 4.
1) Disassemble overflow valve of fuel supply pump.
2) Check inside of overflow valve.
Diagnostic 4 Defective overflow valve
procedures for error Spring or seat is broken or ball is stuck. Defective overflow valve.
code Spring and seat are normal and ball is
not stuck. Overflow valve is normal.

Defective mechanical system of common 2) Loosen joint of common rail pressure limiter.
rail fuel pressure sensor, clogging of over- 3) Start engine.
5 flow piping, defective pressure
limiter, defective electrical system of com- Fuel leaks out. Go to 6.
mon rail fuel pressure sensor
Fuel does not leak out. Go to 7.
2) Perform troubleshooting for error code [DH40KX].
Defective pressure limiter, defective elec-
6 trical system of common rail fuel pressure There is trouble in electrical system. Trouble in electrical system of
sensor common rail fuel pressure sensor.
There is not trouble in electrical sys-
Trouble in pressure limiter.
tem.
Overflow piping is clogged. Clogging in overflow piping.
7 Clogging of overflow piping Trouble in mechanical system of
Overflow piping is not clogged.
common rail fuel pressure sensor.
HM400-1L 20-329 1
• Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter
Disassemble and check the filter. If it is clogged, clean.
2) Upstream strainer of gauze filter
If the gauze filter is clogged, clean the upstream strainer, too.
3) Fuel filter
If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
• Check the low-pressure circuit parts for the following items.
1) Remaining fuel
2) Sticking and wear of feed pump
3) Leakage and clogging of low-pressure fuel piping
4) Defective operation of bypass valve or installation of wrong parts to bypass valve
5) Oil pan oil mixed with fuel (fuel leakage in head cover)
★ Locations of overflow valve ➀ bypass valve ➁, and fuel inlet joint (gauze filter) ➂
• Overflow valve ➀ : Spring is seen through one hole (on nut side).
• Bypass valve ➁ : Spring is seen through both holes.
• Fuel inlet joint ➂ : Gauze filter is seen through both holes.
20-330 1 HM400-1L
12
• Method Of Measuring Fuel Spill Rate
WARNING! Since the fuel is hot max. 90° C (194° F), be careful.
1) Disconnect the hose from the collection part of the return spill tube (at the rear of the engine.
2) Connect a hose to the spill tube end to receive the spilling fuel.
3) Start the engine and stall at each speed and measure the quantity of the fuel spilling in 1 minute.
Limit of fuel spill rate (Total of quantity spilling from 6 cylinders)

Stall Speed (rpm) Limit of Spill Rate
1,600 960 cc/min (32 oz/min)
1,700 1,020 cc/min (35 oz/min)
1,800 1,080 cc/min (37 oz/min)
1,900 1,140 cc/min (39 oz/min)
2,000 1,200 cc/min (41 oz/min)
(ENG-6) FAILURE CODE [AD10MA]

ENG-6 (Fuel supply pump: Function impossible (MA))
★ Nature of failure: Abnormal pressure has occurred in the common rail fuel pressure
★ Carry out troubleshooting for Troubleshooting No. ENG-5 (failure code [AD10L3].
(ENG-7) FAILURE CODE [AD10MB]

ENG-7 (Fuel supply pump: Drop in function (MB))
★ Nature of failure: Non-force feed (level 2) has occurred in the fuel supply pump
★ Carry out troubleshooting for Troubleshooting No. ENG-5 (failure code [AD10L3].
HM400-1L 20-331 1
TROUBLESHOOTING (ENG-8 OR 9) FAILURE CODE [AD11KA] or [AD11KB]
(ENG-8 OR 9) FAILURE CODE [AD11KA] OR [AD11KB]
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM

• Open or short in PVC1 fuel supply pump sensor system.
Contents Of Trouble • ENG code 8 or 9 is displayed.
• Machine not effected. (If error code [AD51KB] is displayed simultaneously engine will stop)

Steps Circuit Diagnostic Procedures For Error Codes [AD11KA] and [AD11KB] Specifications No. Readings
1. PCV 1 Sensor Unit

• Disconnect (PCV1) connector from pump sensor.
At sensor PCV1, between (1) and (2) 2.3 to 5.3Ω 1

A. Sensor test Resistance Ω At sensor PCV1, between (1) or (2)
(OL) open 2
and chassis ground.
A. Open or high Between connectors PCV1, (1) and CN7, (10) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors PCV1, (2) and CN7, (11) 0.0 to 1.0Ω 4
At connector PCV1, between (1) and chassis ground. (OL) open 5
B. Short to chassis
ground or within Resistance Ω At connector PCV1, between (2) and chassis ground. (OL) open 6
harness
At connector PCV1, between (1) and (2) (OL) open 7
Remark
20-332 1 HM400-1L
HM400-1L 20-333 1
(ENG-10 OR 11) FAILURE CODE [AD51KA] OR [AD51KB]
OPEN OR SHORT IN FUEL SUPPLY PUMP PVC1 SYSTEM

• Open or short in PVC1 fuel supply pump sensor system.
Contents Of Trouble • ENG code 10 or 11 is displayed.
• Machine not effected. (If error code [AD11KA] is displayed simultaneously engine will stop)

Steps Circuit Diagnostic Procedures For Error Codes [AD51KA] and [AD51KB] Specifications No. Readings
1. PCV 2 Sensor Unit

At sensor PCV2, between (1) and (2) 2.3 to 5.3Ω 1

A. Sensor test Resistance Ω At sensor PCV2, between (1) or (2)
(OL) open 2
and chassis ground.
• Disconnect (CN7) connector from engine controller and install T-adapter on (CN&CN7) wiring harness connector only.
A. Open or high Between connectors PCV2, (1) and CN7, (4) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors PCV2, (2) and CN7, (12) 0.0 to 1.0Ω 4
At connector PCV2, between (1) and chassis ground. (OL) open 5
B. Short to chassis
ground or within Resistance Ω At connector PCV2, between (2) and chassis ground. (OL) open 6
harness
At connector PCV2, between (1) and (2) (OL) open 7
Remark
20-334 1 HM400-1L
TROUBLESHOOTING (ENG-12) FAILURE CODE [ADA1KA]
(ENG-12) FAILURE CODE [ADA1KA]
OPEN IN NO. 1 INJECTOR SOLENOID VALVE

• Open in No.1injector solenoid valve.
• Engine output lowered

Steps Circuit Diagnostic Procedures For Error Code [ADA1KA] Specifications No. Readings
1. No. 1 Injector Solenoid

• Disconnect (CN1) connector from injector solenoid.
At No.1 injector solenoid CN1, between (1) and (2) 0.4 to 1.1Ω 1
A. Solenoid test Resistance Ω At No.1 injector solenoid CN1, between (1) or (2)
(OL) open 2
and chassis ground.
A. Open or high Between connectors CN6, (7) and CN1, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors CN6, (8) and CN1, (2) 0.0 to 1.0Ω 4
Remark
HM400-1L 20-335 1
TROUBLESHOOTING (ENG-12) FAILURE CODE [ADA1KA]
20-336 1 HM400-1L
TROUBLESHOOTING (ENG-13) FAILURE CODE [ADZKKB]
(ENG-13) FAILURE CODE [ADZKKB]
SHORT CIRCUIT IN NO. 1, 2, 3 INJECTOR SOLENOID VALVE
WARNING! High voltage and amperage are applied to the electrical circuit in the fuel injector system,
be careful when troubleshooting this system, refer to TESTING AND ADJUSTING,
handling high-voltage circuits on engine controller.
• Short in No. 1,2,3 injector solenoid valves.

• Engine output very low

Steps Circuit Diagnostic Procedures For Error Code [ADZKKB] Specifications No. Readings
1. No. 1,2,3 Injector Solenoid

• Disconnect (CN1, CN2, and CN3) connector from injector solenoids.
At sensor CN1, between (1) and (2) 0.4 to 1.1Ω 1


A. Sensor test Resistance Ω
At sensor CN1, between (1) or (2) and chassis ground. (OL) open 4

At connector CN1, between (1) and chassis ground. (OL) open 7
At connector CN1, between (1) and (2) (OL) open 9

A. Short to chassis
ground or within Resistance Ω At connector CN2, between (2) and chassis ground. (OL) open 11
harness
HM400-1L 20-337 1

Remark
Injector #1
Injector #2
20-338 1 HM400-1L
Injector #3
HM400-1L 20-339 1
TROUBLESHOOTING (ENG-14) FAILURE CODE [ADB1KA]
(ENG-14) FAILURE CODE [ADB1KA]

• Open in No.2 injector solenoid valve.

Steps Circuit Diagnostic Procedures For Error Code [ADB1KA] Specifications No. Readings

(OL) open 2
and chassis ground.
Resistance Ω
Remark
20-340 1 HM400-1L
TROUBLESHOOTING (ENG-14) FAILURE CODE [ADB1KA]
HM400-1L 20-341 1
TROUBLESHOOTING (ENG-15) FAILURE CODE [ADC1KA]
(ENG-15) FAILURE CODE [ADC1KA]


Steps Circuit Diagnostic Procedures For Error Code [ADC1KA] Specifications No. Readings

(OL) open 2
and chassis ground.
Resistance Ω
Remark
20-342 1 HM400-1L
TROUBLESHOOTING (ENG-15) FAILURE CODE [ADC1KA]
HM400-1L 20-343 1
TROUBLESHOOTING (ENG-16) FAILURE CODE [ADD1KA]
(ENG-16) FAILURE CODE [ADD1KA]


Steps Circuit Diagnostic Procedures For Error Code [ADD1KA] Specifications No. Readings

(OL) open 2
and chassis ground.
Resistance Ω
Remark
20-344 1 HM400-1L
TROUBLESHOOTING (ENG-16) FAILURE CODE [ADD1KA]
HM400-1L 20-345 1
TROUBLESHOOTING (ENG-17) FAILURE CODE [ADDZKB]
(ENG-17) FAILURE CODE [ADDZKB]
SHORT CIRCUIT IN NO. 4, 5, 6 INJECTOR SOLENOID VALVE
WARNING! Since high voltage and amperage are applied to the electrical circuit in the fuel injector
system, be careful when troubleshooting this system, refer to TESTING AND
ADJUSTING, handling high-voltage circuits on engine controller.
• Short in No. 4,5,6 injector solenoid valves.

• Engine output very low

Steps Circuit Diagnostic Procedures For Error Code [ADDZKB] Specifications No. Readings
1. No. 1,2,3 Injector Solenoid





A. Short to
chassis ground Resistance Ω At connector CN5, between (2) and chassis ground. (OL) open 11
or within harness
20-346 1 HM400-1L

Remark
Injector #4
Injector #5
HM400-1L 20-347 1
Injector #6
20-348 1 HM400-1L
TROUBLESHOOTING (ENG-18) FAILURE CODE [ADE1KA]
(ENG-18) FAILURE CODE [ADE1KA]

• Open in No.5injector solenoid valve.

Steps Circuit Diagnostic Procedures For Error Code [ADE1KA] Specifications No. Readings

(OL) open 2
and chassis ground.
Resistance Ω
Remark
HM400-1L 20-349 1
TROUBLESHOOTING (ENG-18) FAILURE CODE [ADE1KA]
20-350 1 HM400-1L
TROUBLESHOOTING (ENG-19) FAILURE CODE [ADF1KA]
(ENG-19) FAILURE CODE [ADF1KA]


Steps Circuit Diagnostic Procedures For Error Code [ADF1KA] Specifications No. Readings

(OL) open 2
and chassis ground.
Resistance Ω
Remark
HM400-1L 20-351 1
TROUBLESHOOTING (ENG-19) FAILURE CODE [ADF1KA]
20-352 1 HM400-1L
TROUBLESHOOTING (ENG-20) FAILURE CODE [B@BAZG]
(ENG-20) FAILURE CODE [B@BAZG]
ENGINE OIL PRESSURE DROP (ZG)

• Engine oil pressure indicating poorly
• Pressure switch indication irregular

Steps Circuit Diagnostic Procedures For Error Code [B@BAZG] Specifications No. Readings
High idle
Perform a live oil pressure test on engine.
.12 to.18 MPa High idle
(If engine oil pressure is not within listed specifications
Engine Oil Pressure — (30 to 26 psi) 1
do not continue with electrical testing.
Low idle Low idle
See ENGINE SHOP MANUAl)
.07 MPa (10 psi)
1. Defective Pressure Switch

• Disconnect (EG5) pressure switch connector and isolate switches.
At switch EG5 between (12) and chassis ground,

(OL) open 2
engine running at a low idle speed.
A. Pressure switch Resistance Ω
(OL) open 3
engine running at a high idle speed.
• Disconnect (EG5) pressure switches.
A. Open or high Between pressure switch EG5, (12) and CN4, (5) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between pressure switch EG5, (13) and CN4, (6) 0.0 to 1.0Ω 5
At connector EG5, (12) and chassis ground. (OL) open 6

B. Short to
chassis ground Resistance Ω At connector EG5, (13) and chassis ground. (OL) open 7
or within harness
At connector EG5, between (12) and (13) (OL) open 8

Remark
HM400-1L 20-353 1
TROUBLESHOOTING (ENG-20) FAILURE CODE [B@BAZG]
20-354 1 HM400-1L
TROUBLESHOOTING (ENG-21) FAILURE CODE [B@BAZK]
(ENG-21) FAILURE CODE [B@BAZK]
ENGINE OIL LEVEL DROP (ZK)

• Engine oil level indicating poorly
• Level sensor indication irregular

Steps Circuit Diagnostic Procedures For Error Code [B@BAZK] Specifications No. Readings
Engine Oil Level — Check engine oil level Within Spec. 1 Yes or No
1. Defective Level Switch

• Disconnect (OL) level switch connector and isolate switches.
A. Pressure switch Resistance Ω At switch OL, between (22) and chassis ground. (OL) open 2

• Disconnect (OL) level switches.
A. Open or high
Resistance Ω Between level switch OL, (1) and CN6, (1) 0.0 to 1.0Ω 3
resistance
B. Short to
chassis ground Resistance Ω At connector OL, (1) and chassis ground. (OL) open 4
or within harness

Remark
HM400-1L 20-355 1
TROUBLESHOOTING (ENG-22) FAILURE CODE [B@BCNS]
(ENG-22) FAILURE CODE [B@BCNS]
COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)

• Trouble in coolant temperature sensor system.
• Engine coolant temperature showing overheat condition.

Steps Circuit Diagnostic Procedures For Error Code [B@BCNS] Specifications No. Readings
1. Coolant Temperature Sensor Unit

• Disconnect High (TWH) connector from temperature sensor.
At sensor TWH, between (1) and (2) at 10°C (50°F) Approx. 90kΩ 1
A. Sensor test Resistance Ω At sensor TWH, between (1) and (2) at 100°C (212°F) Approx. 3.5kΩ 2
At sensor TWH, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect High (TWH) connector from temperature sensor.
A. Open or high Between connectors TWH, (1) and CN2, (10) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TWH, (2) and CN2, (4) 0.0 to 1.0Ω 5
At connector TWH, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector TWH, between (2) and chassis ground. (OL) open 7
harness
At connector TWH, between (1) and (2) (OL) open 8
Remark
20-356 1 HM400-1L
TROUBLESHOOTING (ENG-22) FAILURE CODE [B@BCNS]
HM400-1L 20-357 1
TROUBLESHOOTING (ENG-23) FAILURE CODE [D181KZ]
(ENG-23) FAILURE CODE [D181KZ]
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)

• Open in or short in pre-heat relay system.
• Engine does not start easily at lower temperatures.

Steps Circuit Diagnostic Procedures For Error Code [D181KZ] Specifications No. Readings
1. Defective Pre-heating Relay

• Replace the relay (R37) with another one of the same type.
• Turn ignition switch “ON”
Voltage Check for voltage at EG1, (3) (check for blown fuse) 20 to 30V 1
— Error code [D181KZ] is displayed. Relay (R37) good 2

A. (R37) relay check
Relay (R37)
— Error code [D181KZ] is not displayed. 3
defective
2. Defective Heater Relay

• With ignition switch in the “OFF” position.
• Locate all connections on (Heater Relay 1,2, and 3).
• Turn ignition switch to “PREHEAT” position
At preheat relay connection (1) and chassis ground. 20 to 30V 4

A. Relay voltage
Voltage At preheat relay connection (2) and chassis ground. 20 to 30V 5
supply

• Disconnect (R37) connector from relay.
• Disconnect (EG4 and EG5) power supply wire to the pre-heater unit.
• Disconnect (CN2 and CN4) connector from engine controller and install T-adapter on (CN2 and CN4) wiring harness connector only.
• ✸ For the voltage test in this step, the ignition switch must be in the “ON” position.
Between connectors R37, (2) and CN2, (5) 0.0 to 1.0Ω 5
A. Open or high Resistance Ω Between connectors R37, (5) and EG4, (31) 0.0 to 1.0Ω 6
resistance Between connectors CN4, (3) and EG5, (11) 0.0 to 1.0Ω 7
Voltage ✸ At connector R37, (1) and (3) to chassis ground. 20 to 30V 8
B. Short to Between connectors R37, (2) and chassis ground. (OL) open 9
chassis ground
or within harness Between connectors R37, (5) and chassis ground. (OL) open 10
Resistance Ω
Between connectors R37, (3)/(5) and chassis ground. (OL) open 11
20-358 1 HM400-1L

Remark
HM400-1L 20-359 1
(ENG-24) FAILURE CODE [D182KZ]
OPEN OR SHORT CIRCUIT IN PRE-HEATING RELAY COIL (KZ)

• Open in or short in pre-heat relay system.
• Engine does not start easily at lower temperatures.

Steps Circuit Diagnostic Procedures For Error Code [D182KZ] Specifications No. Readings
1. Defective Pre-heating Relay

• Replace the relay (R37) with another one of the same type.
Voltage Check for voltage at EG1, (3) (check for blown fuse) 20 to 30V 1
— Error code [D182KZ] is displayed. Relay (R37) good 2

A. (R37) relay check
Relay (R37)
— Error code [D182KZ] is not displayed. 3
defective
2. Defective Heater Relay

• Locate all connections on (Heater Relay 1,2, and 3).
• Turn ignition switch to “PREHEAT” position

A. Relay voltage
Voltage At preheat relay connection (2) and chassis ground. 20 to 30V 5
supply

• Disconnect (EG4 and EG5) power supply wire to the pre-heater unit.
• ✸ For the voltage test in this step, the ignition switch must be in the “ON” position.
Between connectors R37, (2) and CN2, (5) 0.0 to 1.0Ω 5
A. Open or high Resistance Ω Between connectors R37, (5) and EG4, (31) 0.0 to 1.0Ω 6
resistance Between connectors CN4, (3) and EG5, (11) 0.0 to 1.0Ω 7
Voltage ✸ At connector R37, (1) and (3) to chassis ground. 20 to 30V 8
B. Short to Between connectors R37, (2) and chassis ground. (OL) open 9
chassis ground
or within harness Between connectors R37, (5) and chassis ground. (OL) open 10
Resistance Ω
20-360 1 HM400-1L

Remark
HM400-1L 20-361 1
TROUBLESHOOTING (ENG-25) FAILURE CODE [D1D0KB]
(ENG-25) FAILURE CODE [D1D0KB]
SHORT CIRCUIT IN VOLTAGE LOAD POWER SUPPLY (KB)

• Short in voltage load power supply of engine controller system.
• Operates by normal control method.

Steps Circuit Diagnostic Procedures For Error Code [D1D0KB] Specifications No. Readings
1. Defective Relay
• Replace relay (R36) with another one of the same type.
Check for voltage at fuse locations BT2 and (BT4)

Voltage 20 to 30V 1
(check for blown fuse)
Relay (L115)
A. (L115) relay check — Error code [D1D0KB] is displayed. 2 Yes or No
good
Relay (L115)
— Error code [D1D0KB] is not displayed. 3 Yes or No
defective
• Disconnect (R36) connector from relay and (ACC) connection from ignition switch.
• ✸ For the voltage test in this step, the ignition switch must be in the "ON" position.
A. Open or high Resistance Ω Between ignition switch ACC, and CN4, (7) and (18) 0.0 to 1.0Ω 4
resistance Voltage ✸ At connector R36, (3) and chassis ground. 20 to 30V 5
B. Short to Between switch [ACC / R36, (1)]

(OL) open 6
chassis ground and chassis ground.
or within harness Resistance Ω
Between connectors [R36, (5) / CN7, (6),(14)]
(OL) open 7
and chassis ground.
3. Engine Controller Test

• Disconnect connectors (CN4) and (CN7) from controller and install T-adapter on (CN7) and (CN4) wiring harness connector only.
Between CN4 (9), (20) and chassis ground, ignition key

20 to 30V 8
in the ON position.

1 to 0V 9
in the OFF position.
Controller Voltage
20 to 30V 10
in the ON position.

1 to 0V 11
20-362 1 HM400-1L
TROUBLESHOOTING (ENG-25) FAILURE CODE [D1D0KB]
HM400-1L 20-363 1
TROUBLESHOOTING (ENG-26) FAILURE CODE [D5ZAKX]
(ENG-26) FAILURE CODE [D5ZAKX]
ENGINE THROTTLE INPUT SIGNAL OUT OF RANGE (KX)

• Throttle signal out of range.
• Voltage on the throttle side out of range.

Steps Circuit Diagnostic Procedures For Error Code [D5ZAKX] Specifications No. Readings

• Disconnect transmission controller (ATC1, ATC2 and ATC3A) and install T-adapter on wiring harness only.
✸ At connector CN4, (2), (9), (18), (20) and chassis
20 to 30V 1
ground, ignition key in the ON position.
✸ At connector ATC1, (9), (17) and chassis ground,

20 to 30V 2
ignition key in the ON position.
Voltage
✸ At connector ATC1, (7) and chassis ground, ignition
20 to 30V 3
key in the OFF position.
A. Open or high
resistance ✸ At connector ATC2, (1), (12) and chassis ground,
20 to 30V 4
At connector CN4, (8), (19) and chassis ground. 0.0 to 1.0Ω 5
At connector ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 6

Resistance Ω
At connector ATC2, (21) and chassis ground. 0.0 to 1.0Ω 7
Between connector CN4, (16) and ATC3A, (5) 0.0 to 1.0Ω 8
B. Short to
chassis ground Resistance Ω At connector CN4, (16) and chassis ground. (OL) open 9
or within harness
2. Engine Or Transmission Controller Unit

• No testing procedure for the controllers themselve.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Engine or Transmission
Controller Unit. Be sure all steps are completed correctly before faulting the controller unit.
20-364 1 HM400-1L
TROUBLESHOOTING (ENG-26) FAILURE CODE [D5ZAKX]
HM400-1L 20-365 1
TROUBLESHOOTING (ENG-27) FAILURE CODE [DB20KT]
(ENG-27) FAILURE CODE [DB20KT]
CONTROLLER POWER SUPPLY (KT) VOLTAGE IS LOW

• Controller power supply (NSW) voltage low.
• No high idle under load, engine stops, engine cannot be started.

Steps Circuit Diagnostic Procedures For Error Code [DB20KT] Specifications No. Readings

A. Open or high Between connector CN7 (5) and chassis ground. 0.0 to 1.0Ω 1
Resistance Ω
resistance Between connector CN7 (13) and chassis ground. 0.0 to 1.0Ω 2
Remark
20-366 1 HM400-1L
TROUBLESHOOTING (ENG-28) FAILURE CODE [DB22KK]
(ENG-28) FAILURE CODE [DB22KK]
DROP IN VOLTAGE LOAD POWER SUPPLY (KK)

• Short in voltage load power supply of engine controller system.
• Operates by normal control method.

Steps Circuit Diagnostic Procedures For Error Code [DB22KK] Specifications No. Readings
1. Defective Relay
• Replace relay (R36) with another one of the same type.
Check for voltage at fuse locations BT2 and (BT4)

Voltage 20 to 30V 1
(check for blown fuse)
Relay (L115)
A. (L115) relay check — Error code [D1D0KB] is displayed. 2
good
Relay (L115)
— Error code [D1D0KB] is not displayed. 3
defective
• Disconnect (R36) connector from relay and (ACC) connection from ignition switch.
A. Open or high Resistance Ω Between ignition switch ACC, and CN4, (7) and (18) 0.0 to 1.0Ω 4
resistance Voltage ✸ At connector R36, (3) and chassis ground. 20 to 30V 5
B. Short to Between switch [ACC / R36, (1)]

(OL) open 6
chassis ground and chassis ground.
or within harness Resistance Ω
Between connectors [R36, (5) / CN7, (6),(14)]
(OL) open 7
and chassis ground.
3. Engine Controller Test

• Disconnect connectors (CN4) and (CN7) from controller and install T-adapter on (CN7) and (CN4) wiring harness connector only.

20 to 30V 8
in the ON position.

1 to 0V 9
Controller Voltage
20 to 30V 10
in the ON position.

1 to 0V 11
HM400-1L 20-367 1
TROUBLESHOOTING (ENG-28) FAILURE CODE [DB22KK]
20-368 1 HM400-1L
TROUBLESHOOTING (ENG-29) FAILURE CODE [DB29KQ]
(ENG-29) FAILURE CODE [DB29KQ]
NONCONFORMANCE OF MODEL SELECTION SIGNALS IN ENGINE

CONTROLLER WIRING HARNESS (KQ)
• Non conforming of model selection signals in engine controller.
• Normal engine output not obtained.

Steps Circuit Diagnostic Procedures For Error Code [DB29KQ] Specifications No. Readings
1. Defective Model Selection

• Disconnect (MS) connector.
At connector MS, between (1) and (2) 0.0 to 1.0Ω 1

At connector MS, between (3) and (4) (OL) open 2
A. Selection test Resistance Ω

• Disconnect (MS) connector.
Between connectors MS, (4) and CN4, (15) 0.0 to 1.0Ω 5
A. Open or high Between connectors MS, (3) and CN4, (14) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors MS, (2) and CN4, (13) 0.0 to 1.0Ω 7
At connector MS, between (1) and chassis ground. 0.0 to 1.0Ω 8
At connector MS, between (2) and chassis ground. (OL) open 9

At connector MS, between (3) and chassis ground. (OL) open 10
B. Short to chassis At connector MS, between (4) and chassis ground. (OL) open 11
ground or within Resistance Ω
harness At connector MS, between (1) and (2)/(3)/(4) (OL) open 12
At connector MS, between (2) and (3)/(4) (OL) open 13
At connector MS, between (3) and (4) (OL) open 14

Remark
HM400-1L 20-369 1
TROUBLESHOOTING (ENG-29) FAILURE CODE [DB29KQ]
20-370 1 HM400-1L
TROUBLESHOOTING (ENG-30) FAILURE CODE [DB2AMA]
(ENG-30) FAILURE CODE [DB2AMA]
“Q” ADJUSTMENT FOR ENGINE CONTROLLER NOT SET PROPERLY (MA)

Controller
Code Trouble Function of Q adjustment switch of engine controller is defective
E01 DB2AMA ENG-30
Description of • Q adjustment switches of engine controller are not set to proper positions.
Trouble
Controller • Operates by normal control method.
Reaction
Effect on Machine • Setting of Q adjustment switches cannot be changed.
Related • Setting of Q adjustment switches (SW1, SW2) can be checked with monitoring function (Code: 36800)
Information
When normal F position
Setting of SW1 (On back side of
controller) When abnormal Other position than
Diagnostic F
Defective setting of Q adjustment
procedures for 1 switches
error code When normal F position
Setting of SW2 (On back side of
controller When abnormal Other position than
F
2 Defective engine controller —
Related diagram
HM400-1L 20-371 1
TROUBLESHOOTING (ENG-31) FAILURE CODE [KK11KB]
(ENG-31) FAILURE CODE [KK11KB]
TROUBLE IN INPUT OF ignition switch C (KB)

• Short or open in starting system switch C (KB)
• Operates by normal control method

Steps Circuit Diagnostic Procedures For Error Code [KK11KB] Specifications No. Readings
1. Defective Ignition Switch

• Disconnect ignition switch terminal (C)
• Turn ignition switch to the “CRANK” position.
A. Ignition switch Voltage Between switch terminals (C) and chassis ground. 20 to 30V 1

• Disconnect switch terminal (C) from switch.
A. Open or high
Resistance Ω Between ignition switch (C) and CN4, (2) 0.0 to 1.0Ω 2
resistance
B. Short to
chassis ground Resistance Ω Between connector CN4, (2) and chassis ground. (OL) open 3
or within harness

Remark
20-372 1 HM400-1L
TROUBLESHOOTING (ENG-32) FAILURE CODE [DDA1L5]
(ENG-32) FAILURE CODE [DDA1L5]
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (L5)

• Trouble in throttle (Acceleration) sensor system.
• Engine speed is locked between low or high idle, cannot be varied between them.

Steps Circuit Diagnostic Procedures For Error Code [DDA1L5] Specifications No. Readings
1. Throttle Sensor Unit, and Idle Validation Switch

• Disconnect (AS1) connector from throttle sensor and install T-adapter between (AS1) connector and throttle sensor.
• ✸ Turn ignition switch to the “ON” position for this test.
✸ At sensor AS1, between (1) and (2) 0.3 to 4.7V 1
A. Sensor test Voltage
✸ At sensor AS1, between (3) and chassis ground. 4.6 to 5.4V 2
✸ At switch AS1, between (5) and (4) [see table] Signal 2 3

Voltage
B. Idle switch test ✸ At switch AS1, between (6) and (4) [see table] Signal 3 4
Resistance Ω At switch AS1, between (4) and chassis ground. 0.0 to 1.0Ω 5

• Disconnect (AS1) connector from throttle sensor and idle switch unit.
• Disconnect (CN1) and (CN4) connector from engine controller and install T-adapter on (CN1) and (CN4) wiring harness connector only.
Between connectors AS1, (1) and CN1, (11) 0.0 to 1.0Ω 6
A. Open or high Between connectors AS1, (3) and CN1, (4) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors AS1, (4) and CN4, (8) 0.0 to 1.0Ω 9
HM400-1L 20-373 1
TROUBLESHOOTING (ENG-32) FAILURE CODE [DDA1L5]

B. Short to chassis
ground or within Resistance Ω At connector CN4, between (8) and (12) (OL) open 17
harness

Remark
20-374 1 HM400-1L
TROUBLESHOOTING (ENG-33) FAILURE CODE [DDE2L6]
(ENG-33) FAILURE CODE [DDE2L6]
ENGINE OIL PRESSURE DROP (L6)

• Engine oil pressure indicating poorly
• Pressure switch indication irregular

Steps Circuit Diagnostic Procedures For Error Code [B@BAZG] Specifications No. Readings
High idle
Perform a live oil pressure test on engine.
.12 to.18 MPa High idle
(If engine oil pressure is not within listed specifications
Engine Oil Pressure — (30 to 26 psi) 1
do not continue with electrical testing.
Low idle Low idle
See ENGINE SHOP MANUAl)
.07 MPa (10 psi)
1. Defective Pressure Switch

• Disconnect (EG5) pressure switch connector and isolate switches.

0.0 to 1.0Ω 2
engine OFF.

(OL) open 3

(OL) open 4
A. Pressure switch Resistance Ω
0.0 to 1.0Ω 5
engine OFF.

(OL) open 6

(OL) open 6

• Disconnect (EG5) pressure switches.
A. Open or high Between pressure switch EG5, (12) and CN4, (5) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between pressure switch EG5, (13) and CN4, (6) 0.0 to 1.0Ω 9
At connector EG5, (12) and chassis ground. (OL) open 10

B. Short to
chassis ground Resistance Ω At connector EG5, (13) and chassis ground. (OL) open 11
or within harness
At connector EG5, between (12) and (13) (OL) open 12

Remark
HM400-1L 20-375 1
TROUBLESHOOTING (ENG-33) FAILURE CODE [DDE2L6]
20-376 1 HM400-1L
TROUBLESHOOTING (ENG-34) FAILURE CODE [DGE2KX]
(ENG-34) FAILURE CODE [DGE2KX]
COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)

• System showing out of range.

Steps Circuit Diagnostic Procedures For Error Code [DGE2KX] Specifications No. Readings

• Disconnect (TWH) connector from temperature sensor.
At sensor TWH, between (1) and (2) at 10°C (50°F) Approx. 90kΩ 1
A. Sensor test Resistance Ω At sensor TWH, between (1) and (2) at 100°C (212°F) Approx. 0.3kΩ 2
At sensor TWH, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect (TWH) connector from temperature sensor.
A. Open or high Between connectors TWH, (1) and CN2, (4) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TWH, (2) and CN2, (10) 0.0 to 1.0Ω 5
At connector TWH, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector TWH, between (2) and chassis ground. (OL) open 7
harness
At connector TWH, between (1) and (2) (OL) open 8
Remark
HM400-1L 20-377 1
TROUBLESHOOTING (ENG-35) FAILURE CODE [DGE3LC]
(ENG-35) FAILURE CODE [DGE3LC]
COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (L6)

• Sensor indicating out of range.

Steps Circuit Diagnostic Procedures For Error Code [DGE3L6] Specifications No. Readings

• Disconnect (TWL) connector from temperature sensor.
At sensor TWL, between (1) and (2) at 10°C (50°F) Approx. 9kΩ 1
A. Sensor test Resistance Ω At sensor TWL, between (1) and (2) at 100°C (212°F) Approx. 0.3kΩ 2
At sensor TWL, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect (TWL) connector from temperature sensor.
A. Open or high Between connectors TWL, (1) and CN2, (3) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TWL, (2) and CN2, (10) 0.0 to 1.0Ω 5
At connector TWL, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector TWL, between (2) and chassis ground. (OL) open 7
harness
At connector TWL, between (1) and (2) (OL) open 8
Remark
20-378 1 HM400-1L
TROUBLESHOOTING (ENG-36) FAILURE CODE [DGE4KX]
(ENG-36) FAILURE CODE [DGE4KX]
TROUBLE IN FUEL TEMPERATURE SENSOR SYSTEM (KX)

• Trouble in fuel temperature sensor system.
• Output is low ar colder temperatures

Steps Circuit Diagnostic Procedures For Error Code [DGE4KX] Specifications No. Readings
1. Fuel Temperature Sensor Unit

• Disconnect (THL) connector from temperature sensor.
At sensor THL, between (1) and (2) at 10°C (50°F) Approx. 9kΩ 1
A. Sensor test Resistance Ω At sensor THL, between (1) and (2) at 100°C (212°F) Approx. 0.3kΩ 2
At sensor THL, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect (THL) connector from temperature sensor.
A. Open or high Between connectors THL, (1) and CN2, (11) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors THL, (2) and CN2, (10) 0.0 to 1.0Ω 5
At connector THL, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector THL, between (2) and chassis ground. (OL) open 7
harness
At connector THL, between (1) and (2) (OL) open 8
Remark
HM400-1L 20-379 1
TROUBLESHOOTING (ENG-37) FAILURE CODE [DH30KX]
(ENG-37) FAILURE CODE [DH30KX]
TROUBLE IN BOOST PRESSURE SENSOR SYSTEM (KX)

• Trouble in boost air pressure sensor system.
• Output is effected under a load.

Steps Circuit Diagnostic Procedures For Error Code [DH30KX] Specifications No. Readings
1. Boost Pressure Sensor Unit

• Disconnect (PIM) connector from boost air pressure sensor and install T-adapter between (PIM) connector and boost air pressure sensor.
• ✸ For this test the ignition switch must be in the “ON” position.
✸ At sensor PIM, between (1) and (3) 0.3 to 4.7V 1
Voltage
✸ At sensor PIM, between (1) and (2) 4.6 to 5.4V 2
A. Sensor test
At sensor PIM, between (1) and chassis ground. (OL) open 3
Resistance Ω
At sensor PIM, between (2) and chassis ground. (OL) open 4

• Disconnect (PIM) connector from boost air pressure sensor.
Between connectors PIM, (3) and CN2, (10) 0.0 to 1.0Ω 5

A. Open or high
Resistance Ω Between connectors PIM, (2) and CN1, (3) 0.0 to 1.0Ω 6
resistance
.Between connectors PIM, (1) and CN2, (2) 0.0 to 1.0Ω 7
.At connector PIM, between (1) and (2) (OL) open 8
At connector PIM, between (1) or (3) and

(OL) open 9
B. Short to chassis chassis ground.
At connector PIM, between (1) and (3) (OL) open 10
harness
At connector PIM, between (2) and (3) (OL) open 11
At connector PIM, between (2) and chassis ground. (OL) open 12

Remark
20-380 1 HM400-1L
HM400-1L 20-381 1
(ENG-38) FAILURE CODE [DH40KX]
TROUBLE IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM (KX)

• Trouble in common rail fuel pressure sensor system.
• Engine output is effected.

Steps Circuit Diagnostic Procedures For Error Code [DH40KX] Specifications No. Readings
1. Common Rail Pressure Sensor Unit

• Disconnect (PFUEL) connector from common rail fuel pressure sensor and install T-adapter between (PFUEL)
connector and common rail fuel pressure sensor.
• Turn ignition switch to the "ON" position.
At sensor PFUEL between (1) and (3) 4.6 to 5.4V 1

At sensor PFUEL between (1) and (2) 0.3 to 4.7 2
• Disconnect (PFUEL) connector from common rail fuel pressure sensor.
Between connectors PFUEL, (3) and CN2, (10) 0.0 to 1.0Ω 4

A. Open or high
Resistance Ω Between connectors PFUEL, (2) and CN1, (1) 0.0 to 1.0Ω 5
resistance
.Between connectors PFUEL, (1) and CN2, (2) 0.0 to 1.0Ω 6
.At connector PFUEL, between (1) and (2) (OL) open 7
At connector PFUEL, between (1) or (3) and

(OL) open 8
chassis ground
B. Short to chassis
ground or within Resistance Ω At connector PFUEL, between (1) and (3) (OL) open 9
harness
At connector PFUEL, between (2) and (3) (OL) open 10
At connector PFUEL, between (2) and

(OL) open 11
chassis ground

Remark
20-382 1 HM400-1L
HM400-1L 20-383 1
TROUBLESHOOTING (ENG-39) FAILURE CODE [DK10KX]
(ENG-39) FAILURE CODE [DK10KX]
TROUBLE IN THROTTLE (ACCELERATION) SENSOR SYSTEM (KX)

• Trouble in throttle (Acceleration) sensor system.
• Engine speed is locked between low or high idle, cannot be varied between them.

Steps Circuit Diagnostic Procedures For Error Code [DK10KX] Specifications No. Readings

• Disconnect (AS1) connector from throttle sensor and install T-adapter between (AS1) connector and throttle sensor.
✸ At sensor AS1, between (1) and (2) 0.3 to 4.7V 1
✸ At sensor AS1, between (3) and chassis ground. 4.6 to 5.4V 2
✸ At switch AS1, between (5) and (4) [see table] Signal 2 3

Voltage
B. Idle switch test ✸ At switch AS1, between (6) and (4) [see table] Signal 3 4
Resistance Ω At switch AS1, between (4) and chassis ground. 0.0 to 1.0Ω 5

• Disconnect (AS1) connector from throttle sensor and idle switch unit.
• Disconnect (CN1) and (CN4) connector from engine controller and install T-adapter on (CN1) and (CN4) wiring harness connector only.
A. Open or high Between connectors AS1, (3) and CN1, (4) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors AS1, (4) and CN4, (8) 0.0 to 1.0Ω 9
20-384 1 HM400-1L
TROUBLESHOOTING (ENG-39) FAILURE CODE [DK10KX]

B. Short to chassis
ground or within Resistance Ω At connector CN4, between (8) and (12) (OL) open 17
harness

Remark
HM400-1L 20-385 1
TROUBLESHOOTING (ENG-40) FAILURE CODE [DLE3LC]
(ENG-40) FAILURE CODE [DLE3LC]
TROUBLE IN ENGINE NE SPEED SENSOR SYSTEM

• Trouble in NE speed sensor system.
• Engine output is low.

Steps Circuit Diagnostic Procedures For Error Code [DLE3LC] Specifications No. Readings
1. Engine NE Speed Sensor Unit

• Disconnect (NE) connector from speed sensor.
At sensor NE, between (1) and (2) 85 to 210Ω 1

At sensor NE, between (1) or (2) and chassis ground. (OL) open 2

• Disconnect (NE) connector from speed sensor.
A. Open or high Between connectors NE, (1) and CN1, (5) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors NE, (2) and CN1, (12) 0.0 to 1.0Ω 4
At connector NE, between (1) and chassis ground. (OL) open 5

B. Short to chassis
ground or within Resistance Ω At connector NE, between (2) and chassis ground. (OL) open 6
harness
At connector NE, between (1) and (2) (OL) open 7

Remark
20-386 1 HM400-1L
TROUBLESHOOTING (ENG-41) FAILURE CODE [DLE1LC]
12
(ENG-41) FAILURE CODE [DLE1LC]
TROUBLE IN ENGINE G SPEED SENSOR SYSTEM (LC)

• Trouble in G speed sensor system.
• Engine output is low.

Steps Circuit Diagnostic Procedures For Error Code [DLH1LC] Specifications No. Readings
1. Engine G Speed Sensor Unit

• Disconnect (G) connector from speed sensor.
At sensor G, between (1) and (2) 1.4 to 3.5Ω 1

At sensor G, between (1) or (2) and chassis ground. (OL) open 2

• Disconnect (G) connector from speed sensor.
A. Open or high Between connectors G, (1) and CN2, (1) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors G, (2) and CN2, (9) 0.0 to 1.0Ω 4
At connector G, between (1) and chassis ground. (OL) open 5

B. Short to chassis
ground or within Resistance Ω At connector G, between (2) and chassis ground. (OL) open 6
harness
At connector G, between (1) and (2) (OL) open 7

Remark
HM400-1L 20-387 1
TROUBLESHOOTING (ENG-42) NO FAILURE CODE DISPLAYED
12
(ENG-42) NO FAILURE CODE DISPLAYED
ENGINE DOES NOT CRANK

• Open in starter motor circuit.
Contents Of Trouble
• Engine will not crank.

Steps Circuit Diagnostic Procedures For Error Code [ENG-1] Specifications No. Readings
— Check fuses at BT2-20 and BT3-10 Fuse OK? 1 Yes or No

Fuses and Circuit Breaker
— Check circuit breaker Breaker set? 2 Yes or No
1. Defective Battery
• Check all battery connections including engine and ground circuits.
• Check battery specific gravity and load test battery if necessary.
• Disconnect (CN-78) connector from starter motor and install T-adapter between (CN-78) connector.
• ✸ For this test the ignition switch must be in the “ON” position.
✸ Between battery relay terminals (R), (RW),
20 to 30V 3
(B) and battery ground.
✸ Between connector (B) at starter and ground. 20 to 30V 4

A. Open or high Voltage
resistance
✸ At connector CN-78, (1) and ground. 20 to 30V 5
✸ At connector CN-78 (2) and ground key in start

20 to 30V 6
position.
Resistance Ω Between battery relay terminal (V) and ground. 0.0 to 1.0Ω 7
3. Defective R02 Neutral Relay Circuit

• Place shift lever in “NUTRAL” position.
• ✸ Turn ignition switch to the “ON” position.
Voltage ✸ At relay R02, (1) and chassis ground. 20 to 30V 8
A. Relay circuit test
Resistance Ω At relay R02, (2) and chassis ground. 0.0 to 1.0Ω 9
4. Defective R01 Engine Start Relay Circuit

• Place shift lever in “NEUTRAL” position.
• ✸ Turn ignition switch to the “ON” position.
Resistance Ω At relay R01, (2) and chassis ground. 0.0 to 1.0Ω 10
A. Relay circuit test
Voltage ✸ At relay R01, (1) and chassis ground. 20 to 30V 11
5. Defective Ignition Switch Circuit

• Disconnect switch (C) and (B) terminals.
20-388 1 HM400-1L
Voltage At wire terminal (B) and chassis ground. 20 to 30V 12

A. Switch circuit test At switch between terminals (B) and (C) key in the
Resistance Ω 0.0 to 1.0Ω 13
“START” position.
6. Defective Shift Switch Circuit

• Disconnect (SF1) connector from shiftier.
• ✸ For this test the ignition switch must be in the "ON" position.
Voltage ✸ At connector SF1, (1) and ground. 20 to 30V 14
A. Shift Switch At shift lever switch SF1, between (1) and (5), shift
Resistance Ω 0.0 to 1.0Ω 15
lever in “NEUTRAL”
HM400-1L 20-389 1
20-390 1 HM400-1L
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM (TM MODE)

TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411
CONTENT OF CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
(TM-1) FAILURE CODE [1380MW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
LOCK-UP CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
(TM-2) FAILURE CODE [1500LO] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
TRANSMISSION CLUTCH (LO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-448
(TM-3) FAILURE CODE [15BONX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-449
TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX) . . . . . . . . . . . . . . . . . 20-449
(TM-4) FAILURE CODE [15GOMW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-451
“R” CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-451
(TM-5) FAILURE CODE [15HOMW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-453
“HI” CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-453
(TM-6) FAILURE CODE [15JOMW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
“LO” CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-455
(TM-7) FAILURE CODE [15KOMW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-457
1ST CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-457
(TM-8) FAILURE CODE [15LOMW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-459
2ND CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-459
(TM-9) FAILURE CODE [15MOMW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-461
3RD CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-461
(TM-10) FAILURE CODE [15SBL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-463
ECMV FOR “R” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-463
(TM-11) FAILURE CODE [15SBMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-465
ECMV FOR “R” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-465
(TM-12) FAILURE CODE [15SCL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-467
ECMV “HI” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-467
(TM-13) FAILURE CODE [15SCMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-469
ECMV “HI” CLUTCH NOT DISENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-469
(TM-14) FAILURE CODE [15SDL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-471
ECMV “LO” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-471
(TM-15) FAILURE CODE [15SDMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-473
ECMV “LO” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-473
(TM-16) FAILURE CODE [15SEL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-475
ECMV “1st” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-475
(TM-17) FAILURE CODE [15SEMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-477
ECMV “1ST” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-477
(TM-18) FAILURE CODE [15SFL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-479
ECMV “2ND” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-479
(TM-19) FAILURE CODE [15SFMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-481
ECMV “2ND” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-481
(TM-20) FAILURE CODE [15SGL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-483
ECMV “3RD” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-483
(TM-21) FAILURE CODE [15SGMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-485
ECMV “3RD” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-485
(TM-22) FAILURE CODE [15SJL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-487
HM400-1L 20-4011
ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (l1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-487
(TM-23) FAILURE CODE [15SJMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-489
ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-489
(TM-24) FAILURE CODE [15SKL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-491
ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-491
(TM-25) FAILURE CODE [15SKMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-493
ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-493
(TM-26) FAILURE CODE [2B61MW] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-495
ECMV “INTER-AXLE” CLUTCH SLIPPING (MW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-495
(TM-27) FAILURE CODE [2F00KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-497
PARKING BRAKE SYSTEM INDICATING FAILURE (KM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-497
(TM-28) FAILURE CODE [6014NX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-499
HYDRAULUC TANK FILTER CLOGGED (NX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-499
(TM-29) FAILURE CODE [989A00] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-501
POSSIBLE ENGINE OVER SPEED CONDITION (00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-501
(TM-30) FAILURE CODE [989AKZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-502
OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ) . . . . . . . . . . . . . . . . . . . . .20-502
(TM-31)FAILURE CODE [989D00] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-504
REAR OVERTURN SIGNAL OUT OF RANGE (00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-504
(TM-32)FAILURE CODE [AA10NX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-506
AIR CLEANER CLOGG INDICATION (NX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-506
(TM-33) FAILURE CODE [AB00MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-508
ALTERNATOR NOT CHARGING PROPERLY (MA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-508
(TM-34) FAILURE CODE [B@BCZK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-509
COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK) . . . . . . . . . . . . . . . . . . . . . . . . .20-509
(TM-35) FAILURE CODE [B@HAZK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-511
LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-511
(TM-36) FAILURE CODE [B@JANS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-512
STEERING OIL OVERHEAT CONDITION INDICATED (ZK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-512
(TM-37) FAILURE CODE [D1B0KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-513
POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ) . . . . . . . . . . . . . . . .20-513
(TM-38) FAILURE CODE [D5ZBKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-515
DEFFERENTIAL LOCK CIRCUIT SIGNIAL INCORRECT (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-515
(TM-39) FAILURE CODE [D5ZCKZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-517
OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ) . . . . . . . . . . . . . . . . . . . . . . . .20-517
(TM-40) FAILURE CODE [DF10KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-519
FORCED NEUTRAL DEMAND SIGNAL (L4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-519
(TM-41) FAILURE CODE [D5ZEKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-521
ENGINE LOAD SIGNIAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-521
(TM-42) FAILURE CODE [DAQ0KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-523
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK) . . . . . . . . . . . . . . . . . . . . . . . . . .20-523
POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK) . . . . . . . . . . . . . . . . . .20-527
(TM-46) FAILURE CODE [DAQ5KP] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-531
TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP) . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-531
(TM-47) FAILURE CODE [DAQ9KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-533
MISTAKEN OPERATION SETTING (KP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-533
(TM-48) FAILURE CODE [DAQ9KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-534
NO MATCH IN MODEL SELECTION SIGNAL (KP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-534
(TM-49) FAILURE CODE [DAQAKQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
TRANSMISSION CONTROLLER ROTARY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
(TM-50) FAILURE CODE [DAQSMA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
TRANSMISSION FUNCTION INNOPERABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-535
20-402 1 HM400-1L
(TM-51) FAILURE CODE [DDTFKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-536
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . .20-536
(TM-52) FAILURE CODE [DDTFKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-538
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . .20-538
(TM-53) FAILURE CODE [DDTHKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-540
“HI” CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-540
(TM-54) FAILURE CODE [DDTJKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-542
“LO” CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-542
(TM-55) FAILURE CODE [DDTKKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-544
1st CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-544
(TM-56) FAILURE CODE [DDTLKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-546
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-546
(TM-57) FAILURE CODE [DDTMKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-548
3RD CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-548
(TM-58) FAILURE CODE [DDTNKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-550
“R” CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-550
(TM-59) FAILURE CODE [DF10KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-552
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) . . . . . . . . . . . . . . . . . . . . . . .20-552
(TM-60) FAILURE CODE [DF10KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-554
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA) . . . . . . . . . . . . . . . . . . . . . . .20-554
(TM-61) FAILURE CODE [DGF1KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-556
TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . .20-556
(TM-62) FAILURE CODE [DGR2L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-557
REAR BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . . . .20-557
CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . .20-559
FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . . .20-561
(TM-65) FAILURE CODE [DGT1LX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-563
TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . .20-563
(TM-66) FAILURE CODE [DHT5KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-564
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . .20-564
(TM-67) FAILURE CODE [DHT5L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-566
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6) . . . . . . . . . . . . . . . . . . . . . .20-566
(TM-68) FAILURE CODE [DJF1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-568
FUEL LEVEL SENSOR OUT OF RANGE (L6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-568
(TM-69) FAILURE CODE [DK11KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-570
THROTTLE ANGLE SENDOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-570
(TM-70) FAILURE CODE [DLE2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-572
ENGINE SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-572
(TM-71) FAILURE CODE [DLE2LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-573
ENGINE SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-573
(TM-72) FAILURE CODE [DLF1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-574
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . .20-574
(TM-73) FAILURE CODE [DLF1LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-575
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . . . . . . . . . .20-575
(TM-74) FAILURE CODE [DLF2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-576
TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . .20-576
(TM-75) FAILURE CODE [DLF2LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-577
TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . .20-577
(TM-76) FAILURE CODE [DLT3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-578
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . .20-578
(TM-77) FAILURE CODE [DLT3LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-580
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC) . . . . . . . . . . . . . . . .20-580
(TM-78) FAILURE CODE [DXH0KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-582
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . .20-582
(TM-79) FAILURE CODE [DXH0KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-584
HM400-1L 20-403 1
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . .20-584
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-586
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-588
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-590
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-592
LOW CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-594
LOW CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-596
1st CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-598
1st CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-600
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-602
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-604
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-606
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-608
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-610
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-612
(TM-94) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-614
BACK-UP LIGHTS AND ALARM DO NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-614
20-404 1 HM400-1L
HM400-1L 20-405 1
20-406 1 HM400-1L
HM400-1L 20-407 1
20-408 1 HM400-1L
HM400-1L 20-409 1
20-410 1 HM400-1L
TROUBLESHOOTING TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
12
TM MODE CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-411 1
20-412 1 HM400-1L
12
HM400-1L 20-413 1
20-414 1 HM400-1L
HM400-1L 20-415 1
20-416 1 HM400-1L
12
MEMORANDUM
HM400-1L 20-417 1
12
Failure Code Location Of Failure Nature Of Failure Probable Cause
Lock-up clutch: Slipping When there is output to the lock-up • Defective lock-up clutch solenoid
(MW) clutch solenoid, there is an • Excessive resistance in solenoid (+)
abnormality in the value calculated circuit wiring harness
from the signals from the engine • Excessive resistance in solenoid (-)
1380MW
speed sensor, transmission input circuit wiring harness
(TM-1)
shaft speed sensor, transmission • Defective lock-up clutch, pressure
intermediate shaft speed sensor, control valve hydraulic, mechanical
and transmission system
output shaft R speed sensor. • Defective transmission controller
Transmission clutch: * See Fill switch signals have been input • Other problem occurs at same time
Contents (LO) from 2 clutches that do not form a (failure code [15S*L1] is displayed)
1500L0
normal combination. • Defective pressure control valve
(TM-2)
hydraulic, mechanical system
• Defective transmission controller
Transmission oil filter: When the torque converter oil • Clogged transmission oil filter (when
Clogged (NX) temperature is more than 50fC, the actuating system normally)
signal circuit of the transmission • Defective transmission oil filter
filter clogging switch is open (shut clogging switch
15BONX
off from the ground). • Open in switch signal circuit wiring
(TM-3)
harness
• Open in switch GND circuit wiring
harness
R clutch: Slipping (MW) When there is output to the R clutch • Defective R clutch solenoid
solenoid, there is an abnormality in • Excessive resistance in solenoid (+)
the value calculated from the circuit wiring harness
15G0MW signals from the transmission input • Excessive resistance in solenoid (-)
(TM-4) shaft speed sensor, intermediate circuit wiring harness
shaft speed sensor, and output • Defective R clutch, pressure control
shaft R speed sensor. valve hydraulic, mechanical system
Hi clutch: Slipping (MW) When there is output to the Hi • Defective Hi clutch solenoid
clutch solenoid, there is an • Excessive resistance in solenoid (+)
15H0MW from the signals from the • Excessive resistance in solenoid (-)
(TM-5) transmission input shaft speed circuit wiring harness
sensor, intermediate shaft speed • Defective Hi clutch, pressure control
sensor, and output shaft R speed valve hydraulic, mechanical system
sensor. • Defective transmission controller
Lo clutch: Slipping (MW) When there is output to the Lo • Defective Lo clutch solenoid
15J0MW from the signals from the • Excessive resistance in solenoid (-)
sensor, intermediate shaft speed • Defective Lo clutch, pressure control
1st clutch: Slipping (MW) When there is output to the 1st • Defective 1st clutch solenoid
15K0MW from the signals from the • Excessive resistance in solenoid (-)
sensor, intermediate shaft speed • Defective 1st clutch, pressure control
20-418 1 HM400-1L
12
Action
Code
• Solenoid resistance value • Holds speed range during travel, • Lock-up is canceled and
L/U-PS (male) (1) - (2): 5 - 15 Ω turns lock-up actuation OFF. transmission cannot be shifted
• Holds at Neutral if gearshift lever is • If gearshift lever is operated to N,
operated to N. machine cannot move off again until
it is stopped E03
• Turns transmission cut relay OFF. • Suddenly shifts to Neutral when

• Sets transmission to Neutral. traveling and cannot move off again
E03
• Switch resistance value • Takes no action • If machine continues to be used as it

T03 (male) (1) - (2): is, there is danger that dirt will
• When normal: Max. 1 Ω circulate in transmission circuit
• When clogged: Min. 1 MΩ
E01
Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
R-PS (male) (1) - (2): 5 - 15 Ω traveling
E03
• Solenoid resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
H-PS (male) (1) - (2): 5 - 15 Ω traveling
• Cannot move off again unless
machine is stopped
E03
L-PS (male) (1) - (2): 5 - 15 Ω traveling
machine is stopped
E03
1-PS (male) (1) - (2): 5 - 15 Ω traveling
E03
HM400-1L 20-419 1
2nd clutch: Slipping (MW) When there is output to the 2nd • Defective 2nd clutch solenoid
15L0MW from the signals from the • Excessive resistance in solenoid (-)
sensor, intermediate shaft speed • Defective 2nd clutch, pressure control
(TM-9) 3rd clutch: Slipping When there is output to the 3rd • Defective 3rd clutch solenoid
(MW) clutch solenoid, there is an • Excessive resistance in solenoid (+)
15M0MW from the signals from the • Excessive resistance in solenoid (-)
sensor, intermediate shaft speed • Defective 3rd clutch, pressure control
ECMV for R clutch: * See Even when the output to the R • Defective R clutch fill switch
Contents (L1) clutch solenoid is turned OFF, the • Short circuit with chassis ground in
15SBL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-10) and the clutch is not disengaged. • Defective R clutch pressure control
valve hydraulic, mechanical system
ECMV for R clutch: Function Even when there is output to the R • Defective R clutch solenoid
impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
fill switch stays OFF and the clutch circuit wiring harness
15SBMA is not engaged. • Excessive resistance in solenoid (-)
(TM-11) circuit wiring harness
• Defective R clutch or pressure control
ECMV for Hi clutch: * See Even when the output to the Hi • Defective Hi clutch fill switch
15SCL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-12) and the clutch is not disengaged. • Defective Hi clutch or pressure control
ECMV for Hi clutch: Function Even when there is output to the Hi • Defective Hi clutch solenoid
impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
15SCMA is not engaged. • Excessive resistance in solenoid (-)
• Defective Hi clutch pressure control
ECMV for Lo clutch: * See Even when the output to the Lo • Defective Lo clutch fill switch
15SDL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-14) and the clutch is not disengaged. • Defective Lo clutch pressure control
20-420 1 HM400-1L
12
Action
Code
E03
E03
Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
R-SW (male) (1) - ground: traveling
• When clutch is released: Min. • Cannot move off again unless
E03
1 MΩ machine is stopped
• When clutch is engaged: Max. 1
Ω
R-PS (male) (1) - (2): 5 - 15 Ω traveling
machine is stopped
E03
• Switch resistance value • Sets transmission to Neutral. • Suddenly shifts to Neutral when
H-SW (male) (1) - ground: traveling
E03
Ω
H-PS (male) (1) - (2): 5 - 15 Ω traveling
machine is stopped
E03
L-SW (male) (1) - ground: traveling
• When clutch is released: Min. 1 • Cannot move off again unless
E03
Ω machine is stopped
Ω
HM400-1L 20-421 1
12
ECMV for Lo clutch: Func- Even when there is output to the Lo • Defective Lo clutch solenoid
tion impossible (MA) clutch solenoid, the signal from the • Excessive resistance in solenoid (+)
15SDMA is not engaged. • Excessive resistance in solenoid (-)
• Defective Lo clutch or pressure control
ECMV for 1st clutch: * See Even when the output to the 1st • Defective 1st clutch fill switch
15SEL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-16) and the clutch is not disengaged. • Defective 1st clutch pressure control
ECMV for 1st clutch: Func- Even when there is output to the 1st • Defective 1st clutch solenoid
15SEMA is not engaged. • Excessive resistance in solenoid (-)
• Defective 1st clutch or pressure control
ECMV for 2nd clutch: * See Even when the output to the 2nd • Defective 2nd clutch fill switch
15SFL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-18) and the clutch is not disengaged. • Defective 2nd clutch pressure control
ECMV for 2nd clutch: Func- Even when there is output to the • Defective 2nd clutch solenoid
tion impossible (MA) 2nd clutch solenoid, the signal from • Excessive resistance in solenoid (+)
the fill switch stays OFF and the circuit wiring harness
clutch is not engaged. • Excessive resistance in solenoid (-)
15SFMA
(TM-19)
• Defective 2nd clutch or pressure
control valve hydraulic, mechanical
system
ECMV for 3rd clutch: * See Even when the output to the 3rd • Defective 3rd clutch fill switch
15SGL1 signal from the fill switch stays ON switch circuit wiring harness
(TM-20) and the clutch is not disengaged. • Defective 3rd clutch pressure control
ECMV for 3rd clutch: Func- Even when there is output to the 3rd • Defective 3rd clutch solenoid
15SGMA is not engaged. • Excessive resistance in solenoid (-)
• Defective 3rd clutch or pressure control
20-422 1 HM400-1L
12
Action
Code
L-PS (male) (1) - (2): 5 - 15 Ω traveling
machine is stopped
E03
1-SW (male) (1) - ground: traveling
E03
Ω
machine is stopped
E03
E03
Ω
machine is stopped
E03
E03
Ω
machine is stopped
E03
HM400-1L 20-423 1
12
ECMV for lock-up clutch: * Even when the out put to the lock- • Defective lock-up clutch fill switch
See Contents (L1) up clutch solenoid is turned OFF, • Short circuit with chassis ground in
the signal from the fill switch stays switch circuit wiring harness
15SJL1
ON and the clutch is not • Defective lock-up clutch pressure
(TM-22)
disengaged. control valve hydraulic, mechanical
system
ECMV for lock-up clutch: Even when there is output to the • Defective lock-up clutch solenoid
Function impossible (MA) lock-up clutch solenoid, the signal • Excessive resistance in solenoid (+)
from the fill switch stays OFF and circuit wiring harness
the clutch is not engaged. • Excessive resistance in solenoid (-)
15SJMA
(TM-23)
• Defective lock-up clutch or pressure
control valve hydraulic, mechanical
system
ECMV for inter-axle differen- Even when the output to the • Defective differential lock clutch fill
tial lock clutch: * See Con- differential lock clutch solenoid is switch
tents (L1) turned OFF, the signal from the fill • Short circuit with chassis ground in
15SKL1 switch stays ON and the clutch is switch circuit wiring harness
(TM-24) not disengaged. • Defective differential lock clutch
pressure control valve hydraulic,
mechanical system
ECMV for inter-axle differen- Even when there is output to the • Defective differential lock clutch
tial lock clutch: Function differential lock clutch solenoid, the solenoid
impossible (MA) signal from the fill switch stays OFF • Excessive resistance in solenoid (+)
and the clutch is not engaged. circuit wiring harness
15SKMA • Excessive resistance in solenoid (-)
• Defective differential lock clutch or
pressure control valve hydraulic,
mechanical system
Inter-axle differential lock When there is output to the differen- • Defective differential lock clutch
clutch: Slipping (MW) tial lock clutch solenoid, there is an solenoid
abnormality in the value calculated • Excessive resistance in solenoid (+)
from the signals from the transmis- circuit wiring harness
2B61MW sion output shaft F speed sensor • Excessive resistance in solenoid (-)
(TM-26) and output shaft R speed sensor circuit wiring harness
(retarder controller is responsible • Defective differential lock clutch or
for calculating value). pressure control valve hydraulic,
mechanical system
Parking brake: Mistaken Travel operation was carried out • Forgot to release parking brake (when
operation or mistaken setting when parking brake signal circuit system is working normally)
(KM) was closed (connected with ground) • Blown fuse
• Defective parking brake oil pressure
switch
2F00KM
• Defective parking brake relay
(TM-27)
ground in switch power source circuit
wiring harness
• Open in relay GND circuit wiring
harness
20-424 1 HM400-1L
12
Action
Code
• Switch resistance value • Holds speed range when traveling • Lock-up is canceled and it becomes
L/U-SW (male) (1) - ground: and turns lock-up actuation OFF impossible to shift gear
• When clutch is released: Min. • When gearshift lever is returned to • If gearshift lever is returned to N,
1 MΩ N, holds in Neutral machine cannot move off again until E03
• When clutch is engaged: Max. 1 it is stopped
Ω • Lock-up pilot lamp does not give
display normally
• Solenoid resistance value • Holds speed range when traveling • Lock-up is canceled and it becomes
L/U-PS (male) (1) - (2): 5 - 15 Ω and turns lock-up actuation OFF impossible to shift gear
• When gearshift lever is returned to • If gearshift lever is returned to N,
N, holds in Neutral machine cannot move off again until
it is stopped E03
• Switch resistance value • Turns inter-axle differential lock • Inter-axle differential lock does not
D/L-SW (male) (1) - ground: command OFF work
• When clutch is released: Min.
1 MΩ
E03
Ω
• Solenoid resistance value • Turns inter-axle differential lock • Inter-axle differential lock does not
D/L-PS (male) (1) - (2) : 5 - 15 Ω command OFF work
E01
D/L-PS (male) (1) - (2) : 5 - 15 Ω command OFF work
E01
• Switch resistance value • Takes no action • If the machine is used as it is, there
B17 (male) (1) - (2) : • User code is not displayed is danger that the parking brake may
• Brake released: Min. 1 MΩ be damaged
• Brake applied: Max. 1 Ω
• Relay resistance value
R32 (male) (1) - (2) : 100 - 500 Ω None
HM400-1L 20-425 1
12
Hydraulic tank filter: Clogged When the torque converter oil • Clogged hydraulic oil filter (when
(NX) temperature is more than 50fC, the system is working normally)
6014NX signal circuit of the transmission • Defective hydraulic oil filter clogging
(TM-28) filter clogging switch is open (shut switch
off from the ground). • Open in switch circuit wiring harness
Engine overrun prevention The transmission input shaft speed • Engine overrun
989A00 command signal: Actuated became more than 2450 rpm when • Defective transmission controller
(TM-29) (00) the speed range was other than
Neutral.
Engine overrun prevention Open, short circuit with ground, • Defective retarder controller
command signal: Open or short circuit with power source • Open, short circuit with chassis ground,
989AKZ
short circuit (KZ) occurred in overrun prevention or short circuit with power source in
(TM-30)
command circuit, or did not match signal circuit wiring harness
communications data (S-NET) • Defective transmission controller
Rear overturn signal: Actu- Dump body was operated to RAISE • Dump operated when machine is
ated (00) when machine was inclined more inclined (when system is working
than 15O normally)
• Defective inclination sensor
• Open or short circuit with power source
in sensor power source circuit wiring
989D00
harness
(TM-31)
• Open in sensor GND circuit wiring
harness
• Open, short circuit with chassis ground,
or short circuit with power source in
Air cleaner element: Clogged Air cleaner clogging signal circuit • Clogged air cleaner element (when
(NX) became open (shut off from system is working normally)
ground) when engine was running • Defective air cleaner clogging sensor
• Defective dust indicator relay
• Short circuit with chassis ground in
AA10NX
(TM-32)
• Open in relay signal circuit wiring
harness
harness
Alternator: Function impossi- Electricity generation signal was not • Defective alternator
ble (MA) input from alternator when engine • Open or short circuit with chassis
AB00MA was running. ground in alternator signal circuit
(TM-33) • Defective transmission controller
Radiator water: Drop in level Radiator water level switch signal • Drop in radiator water level (when
(ZK) circuit became open (shut off from system is working normally)
ground) when engine was running • Defective radiator water level switch
B@BCZK • Open in switch signal circuit wiring
(TM-34) harness
harness
20-426 1 HM400-1L
12
Action
Code
• Sensor resistance value • Takes no action • If the machine is used as it is, dirt
T05 (male) (1) - (2) may circulate in the dump circuit
• When normal: Max. 1 Ω
E01
• Issues order to retarder controller to • Brake is applied, travel speed is

apply brake (retarder) reduced
E02
• Signal voltage • Continues control with signal on S- • No great effect on machine

ATC1 (13) - (8)(16) NET
• When command is ON: 20 - 30 E01
V
• When command is OFF: 1 V
• A. Sensor power source voltage • Takes no action • If the dump RAISE operation is
T10 (1) - (3): 11 - 13 V • User code is not displayed continued in this condition, the
• Sensor signal voltage machine may tip over
T10 (2) - (3):
• When machine is horizontal:
2.9 - 3.1 V
• When machine is inclined 15o None
to left: 1.4 - 1.6 V
• When machine is inclined 15o
to right: 4.4 - 4.6 V
• Sensor resistance value • Takes no action • If the machine is used as it is, the
T11 (male) (1) - (2) engine air intake capacity may drop
• When normal: Min. 1 MΩ
• When clogged: Max. 1 Ω
• Relay resistance value
R32 (male) (3) - (6): Max. 1 Ω E01
• Alternator generating voltage • Takes no action • If the machine is used as it is, the
Alternator R - E: 27.5 - 29.5 V power supply voltage will drop and it
may become impossible for the
E03
machine to travel
• Dump body cannot be controlled
(Dump body does not move).
• Sensor resistance value • Takes no action • If the machine is used as it is, the
T01 (male) (1) - (2): engine may overheat
• When normal: Max. 1 Ω
E01
HM400-1L 20-427 1
12
Hydraulic tank oil: Drop in When the engine was stopped, the • Drop in hydraulic tank oil level (when
level (ZK) signal circuit of the hydraulic tank system is working normally)
B@HAZK
level switch became open (shut off • Defective hydraulic tank level switch
(TM-35)
from GND) • Open in switch circuit wiring harness
Steering oil: Overheat (ZK) The signal circuit of the steering oil • Steering oil temperature overheating
temperature switch became open (when system is working normally)
B@JANS (shut off from GND) • Defective steering oil temperature
(TM-36) switch
• Open in switch circuit wiring harness
Transmission cut relay: Open Abnormal voltage was generated in • Defective transmission cut relay
or short circuit (KZ) the transmission cut relay circuit • Open or short circuit with chassis
When relay is actuated: 10 V or ground in relay power source circuit
more wiring harness
D180KZ
When relay is stopped: Less than 4 • Open or short circuit with chassis
(TM-37)
V ground, or short circuit with power
source in relay output circuit wiring
harness
Inter-axle differential lock The voltage in the differential lock • Defective retarder controller
command signal: Input signal signal circuit became less than 0.5 • Open, short circuit with chassis ground,
D5ZBKX
outside range (KX) V or more than 4.5 V or short circuit with power source in
(TM-38)
signal circuit wiring harness
Exhaust brake command sig- Open or Openshort circuit with • Defective retarder controller
nal: Open or short circuit ground, or short circuit with power • Open or short circuit with chassis
D5ZCKZ (KZ) source was generated in the ground, or short circuit with power
(TM-39) exhaust brake command circuit, or source in signal circuit wiring harness
there was a mismatch with the • Defective transmission controller
communication (S-NET) data
Forced neutral demand sig- There was a mismatch between • Defective retarder controller
nal: * See Contents (L4) forced neutral demand signal 1 and • Open or short circuit with chassis
signal 2 ground, or short circuit with power
D5ZDL4 source in signal 1 circuit wiring harness
(TM-40) • Open or short circuit with chassis
ground, or short circuit with power
source in signal 2 circuit wiring harness
Engine load signal: Input sig- The engine load signal circuit was • Defective engine controller
nal outside range (KX) outside the correct range • Open or short circuit with chassis
D5ZEKX
(TM-41)
source in signal circuit wiring harness
Transmission controller: When the engine was running, both • Another problem is occurring at the
Drop in power source volt- the main power supply voltage same time (failure code displayed)
DAQ0KK
age, input (KK) circuit and the direct power supply • Battery tends to lose power
(TM-42)
voltage circuit became less than 18 • Open or short circuit in wiring harness
V • Defective transmission controller
20-428 1 HM400-1L
12
Action
Code
• Sensor resistance value • Takes no action • If the machine is used as it is, it may
T06 (male) (1) - ground: become impossible to carry out
• When oil level is normal: 1 Ω dump operations E01
• When oil level has dropped:
Min. 1 MΩ
• Sensor resistance value • Takes no action • If the machine is used as it is, oil
T04 (male) (1) - ground: leakage may occur
• When oil temperature is 25OC:
E02
Max 1 Ω
• When oil temperature is
123OC: Min. 1 MΩ
• Controller inlet voltage • Turns transmission cut relay OFF. • Suddenly shifts to Neutral when
ATC1 (15) - (8)(16): • Sets transmission to Neutral. traveling and machine cannot move
• When relay actuated: Max. 1 off again
V
• When relay stopped: 20 - 30 V E03
• Signal voltage • Turns inter-axle differential lock • Inter-axle differential lock does not
ATC3A (8) - (18): 0.47 - 4.3 V command OFF work
E01
• Signal voltage • Continues control with signal on S- • No great effect on machine

ATC1 (14) - (8)(16): NET
• When command is OFF: Max. 1
E01
V
• When command is ON: 20 - 30
V
• Continues control with signal on S- No great effect on machine
NET
E01
• Signal voltage • Carries out control with load taken • Gearshift feeling may change
ATC3A (4) - (16): 0 - 15 V as heavy load slightly
E01
• Main power source voltage • Sets transmission to Neutral. • Suddenly shifts to Neutral when
ATC (9)(17) - (8)(16): 20 - 30 V traveling and machine cannot move
• Direct power source voltage off again E03
ATC1 (7) - (8)(16): 20 - 30 V
HM400-1L 20-429 1
12
Transmission controller main The voltage difference between the • Open or short circuit with chassis
DAQ1KK power supply line: Drop in main power supply voltage circuit ground in main power source circuit
(TM-43) power source voltage, input and the direct power supply voltage wiring harness
(KK) circuit became more than 5 V • Defective transmission controller
Transmission controller load When the controller power supply • Defective transmission cut relay
power supply line: Drop in voltage circuit was normal, the • Open or short circuit with chassis
power source voltage, input solenoid power supply voltage ground in relay power source circuit
DAQ2KK (KK) circuit became less than 18 V wiring harness
ground in relay output circuit wiring
harness
Transmission controller bat- The voltage in the direct power • Open or short circuit with chassis
DAQ3KK tery direct power supply line: supply voltage circuit became less ground in direct power source circuit
(TM-45) Drop in power source volt- than 5 V wiring harness
age, input (KK) • Defective transmission controller
Transmission controller The voltage in the 12V power • Defective inclination sensor
power supply output 1: Drop supply circuit for the sensor became • Short circuit with chassis ground in
DAQ5KP
in output voltage (KP) less than 6 V sensor power source circuit wiring
(TM-46)
harness
Transmission controller wir- When the ignition switch is ON, the • Mistaken connection of connector
ing harness: Mistaken opera- input connector check signal does ATC3 (A, B) and connector ATC5 (A, B)
DAQ9KM
tion or mistaken setting (KP) not match the setting inside the (when system is working normally)
(TM-47)
controller • Open in signal 1 circuit wiring harness
Transmission controller wir- When the ignition switch is ON, the • Open in model selection signal circuit
DAQ9KQ ing harness: Non match in input model selection signal is wiring harness
(TM-48) model selection signal (KP) different from the setting of the • Defective transmission controller
controller
Transmission controller The model setting of the rotary • Defective setting of rotary switch
DAQAKQ
rotary switch: Non match in switch does not match the setting • Defective transmission controller
(TM-49)
model selection signal (KP) inside the controller
Transmission controller: The communication (S-NET) with • Another problem is occurring at the
Function impossible (MA) the machine monitor is defective same time (failure code DAQSKR is
DAQSMA
and the option setting cannot be displayed)
(TM-50)
made • Defective machine monitor
Fill switch for inter-axle differ- When the output is made to the • Defective differential clutch fill switch
ential lock clutch: Open (KA) differential lock clutch solenoid, the • Open or short circuit with power source
DDTFKA
clutch engages, but the signal from in switch circuit wiring harness
(TM-51)
the fill switch does not come ON • Defective transmission controller
20-430 1 HM400-1L
12
Action
Code
• Main power source voltage • Does not allow updating of input • Condition before problem occurred
ATC1 (9)(17) - (8)(16): 20 - 30 V related data is maintained
E03
• Solenoid power source voltage • Turns transmission cut relay OFF. • Suddenly shifts to Neutral when
ATC2 (1)(12) - ATC1 (8)(16): 20 • Sets transmission to Neutral. traveling and machine cannot move
- 30 V off again
E03
• Direct power source voltage • Sets transmission to Neutral. • Suddenly shifts to Neutral when
ATC1 (7) - (8)(16): 20 - 30 V traveling and machine cannot move
E03
off again
• Controller output voltage • Shuts off output of sensor 12V • Does not judge rear overturn alarm
ATC2 (14) - ATC3A (16): 11 - 13 power supply
V E03
• Wiring harness resistance value • Turns transmission cut relay OFF. • Machine does not move off even
ATC5A (female) (1) - ground: • Holds transmission in Neutral. when operation is carried out to
Max. 1 Ω • Does not record in trouble data. move machine off E03
• Wiring harness resistance value • Turns transmission cut relay OFF. • Machine does not move off even
ATC5B (female) (14)(15)(16) - • Holds transmission in Neutral. when operation is carried out to
E03
ground: Max. 1 Ω • Does not record in trouble data. move machine off
• Rotary switch setting position • Turns transmission cut relay OFF. • Machine does not move off even
See TESTING AND • Holds transmission in Neutral. when operation is carried out to E03
ADJUSTING. • Does not record in trouble data. move machine off
• Sets transmission to Neutral. • Machine does not move off even
when operation is carried out to
move machine off E03
• Fill switch resistance value • Takes no action • Inter-axle differential lock is

ATC5A (male) (17) - ground: actuated, but pilot lamp does not
• When clutch is released: Min. light up E01
1 MΩ
• When clutch is engaged: 1 Ω
HM400-1L 20-431 1
12
Fill switch for lock-up clutch: When the output is made to the • Defective lock-up clutch fill switch
Open (KA) lock-up clutch solenoid, the clutch • Open or short circuit with power source
DDTGKA
engages, but the signal from the fill in switch circuit wiring harness
(TM-52)
switch does not come ON • Defective transmission controller
Fill switch for Hi clutch: When the output is made to the Hi • Defective Hi clutch fill switch
Open (KA) clutch solenoid, the clutch engages, • Open or short circuit with power source
DDTHKA
but the signal from the fill switch in switch circuit wiring harness
(TM-53)
does not come ON • Defective transmission controller
Fill switch for Lo clutch: When the output is made to the Lo • Defective Lo clutch fill switch
DDTJKA
(TM-54)
•
Fill switch for 1st clutch: When the output is made to the 1st • Defective 1st clutch fill switch
DDTKKA
(TM-55)
•
Fill switch for 2nd clutch: When the output is made to the 2nd • Defective 2nd clutch fill switch
DDTLKA
(TM-56)
•
Fill switch for 3rd clutch: When the output is made to the 3rd • Defective 3rd clutch fill switch
DDTMKA
(TM-57)
Fill switch for R clutch: When the output is made to the R • Defective R clutch fill switch
DDTNKA does not come ON • Defective transmission controller
(TM-58)
Gearshift lever: Open (KA) Nothing is input for the gearshift • Defective gearshift lever
lever signal • Open or short circuit with chassis
ground in lever power source circuit
wiring harness
DF10KA • Open in lever GND circuit wiring
(TM-59) harness
ground in lever signal circuit wiring
harness
20-432 1 HM400-1L
12
Action
Code
• Fill switch resistance value • Holds speed range during travel • Cannot shift gear
ATC5A (male) (11) - ground: • When gearshift lever is returned to • If gearshift lever is returned to N,
• When clutch is released: N, holds in Neutral machine cannot move off again until E03
Min. 1 MΩ it is stopped
• When clutch is engaged: 1 Ω • Lock-up pilot lamp does not light up
• When clutch is released: N, holds in Neutral machine cannot move off again until
E03
Ω
• When clutch is released: N, holds in Neutral machine cannot move off again until
Min. 1 MΩ it is stopped E03
Ω
• Gearshift lever power source • Condition before abnormality • Shifts to higher speed range than
voltage occurred is maintained speed range set by gearshift lever
SF1 (1) - (2): 20 - 24 V • Stays in Neutral and machine cannot
• Gearshift lever signal voltage move off
• SF1 • Impossible to change direction of
E03
(3)(4)(5)(6)(7)(8)(9)(10)(11) - travel between FORWARD and
(2): REVERSE
• Selected circuit: 20 - 24 V • All gearshift lever position lamps go
• Not selected circuit: Max. 1 V out
HM400-1L 20-433 1
12
Gearshift lever: Short circuit The gearshift lever signal was input • Defective shift lever
(KB) at the same time from 2 or more • Short circuit with power source in lever
systems signal circuit wiring harness
DF10KB
(TM-60)
Transmission valve oil tem- The voltage of the signal circuit for • Defective transmission valve oil
perature sensor: Input signal the transmission valve oil temperature sensor
outside range (KX) temperature sensor became less • Open or short circuit with chassis
than 0.97 V, or there was a big ground, or short circuit with power
DGF1KX
difference from the torque converter source in sensor signal circuit wiring
(TM-61)
oil temperature harness
harness
Brake oil temperature sensor When the front brake oil • Defective rear brake oil temperature
(rear): * See Contents (L8) temperature sensor signal and sensor
center brake oil temperature sensor • Open or short circuit with power source
DGR2L8
signal were more than 60oC, the in sensor signal circuit wiring harness
(TM-62)
rear brake oil temperature sensor • Open in sensor GND circuit wiring
was less than 10OC harness
Brake oil temperature sensor When the front brake oil • Defective center brake oil temperature
(center): * See Contents (L8) temperature sensor signal and rear sensor
brake oil temperature sensor signal • Open or short circuit with power source
DGR3L8
were more than 60oC, the center in sensor signal circuit wiring harness
(TM-63)
brake oil temperature sensor was • Open in sensor GND circuit wiring
OC harness
less than 10
Brake oil temperature sensor When the center brake oil • Defective front brake oil temperature
(front): * See Contents (L8) temperature sensor signal and rear sensor
brake oil temperature sensor signal • Open or short circuit with power source
DGR4L8
were more than 60oC, the front in sensor signal circuit wiring harness
(TM-64)
brake oil temperature sensor was • Open in sensor GND circuit wiring
oC harness
less than 10
Torque converter oil temper- The voltage of the signal circuit for • Defective torque converter oil
ature sensor: Input signal the torque converter oil temperature temperature sensor
outside range (KX) sensor became less than 0.97 V, or • Open or short circuit with chassis
DGT1KX there was a big difference from the ground, or short circuit with power
(TM-65) transmission valve oil temperature source in sensor signal circuit wiring
sensor signal harness
• Open in sensor GND circuit
Torque converter oil pressure The voltage in the signal circuit of • Defective torque converter oil pressure
sensor: Input signal outside the torque converter oil pressure sensor
range (KX) sensor became less than 0.5 V or • Open or short circuit with chassis
more than 4.5 V ground in sensor power source circuit
DHT5KX wiring harness
source in sensor signal circuit wiring
harness
20-434 1 HM400-1L
12
Action
Code
• Gearshift lever power source • Controls using signal in order of • Shifts to higher speed range than
voltage high priority speed range set by gearshift lever
SF1 (1) - (2): 20 - 24V • (1): N > D > 5 > 4 > 3 > 2 > 1 • Stays in Neutral and machine cannot
• Gearshift lever signal voltage• (2): N > R2 > R1 move off E03
• SF1(3)(4)(5)(6)(7)(8)(9)(10)(11)
• If the signal for both system (1) and • Gearshift lever position lamps are
• Selected circuit: 20 - 24 V system (2) are input at the same different from position of lever
• Not selected circuit: Max. 1 V time, shifts transmission to Neutral
• Sensor resistance value • Controls clutch oil pressure with • Transmission shock becomes
LUB-T (male) (1) - (2): clutch oil temperature before excessive
• When oil temperature is 25oC: abnormality occurred
37 - 50 kΩ
• When oil temperature is E03
100oC: 3.5 - 4.0 kΩ
• Sensor resistance value • Takes no action • Retarder oil temperature gauge

T13 (male) (1) - (2): does not give correct display
• When oil temperature is 25oC: • If it is used as it is, the braking effect
37 - 50 kΩ may become weaker E01
100oC: 3.5 - 4.0 kΩ

100oC:
3.5 - 4.0 kΩ
100oC:
3.5 - 4.0 kΩ
• Sensor resistance value • Takes no action • Torque converter oil temperature
TC-SE (male) (1) - (2): gauge does not give correct display
• When oil temperature is 25oC: If it is used as it is, the braking effect
37 - 50 kΩ may become weaker
E01
100oC:
3.5 - 4.0 kΩ
• Sensor power source voltage • Fixes torque converter oil pressure • Excessive shock when lock-up is
TC-INT (2) - (1): 20 - 30 V to oil pressure set inside controller actuated
• Sensor signal voltage and carries out control
TC-INT (3) - (1): 0.8 - 2.0 V
E01
HM400-1L 20-435 1
12
Torque converter oil pressure When the engine is stopped, the • Defective torque converter oil pressure
sensor: * See Contents (L6) torque converter oil pressure circuit (when actuating system
sensor signal circuit inputs the oil normally)
DHT5L6 pressure • Defective torque converter oil pressure
(TM-67) sensor
Fuel level sensor: Open (L6) The voltage of the signal circuit of • Defective fuel level sensor
the fuel level sensor became more • Open or short circuit with power source
DJF1KA than 4.0 V in sensor signal circuit wiring harness
(TM-68) • Open in sensor GND circuit wiring
harness
Throttle angle sensor: Input The voltage in the signal circuit of • Defective accelerator sensor or
signal outside range (KX) the acceleration sensor became defective accelerator pedal
less than 0.6 V or more than 4.7 V • Open or short circuit with chassis
source in sensor power source circuit
wiring harness
DK11KX
(TM-69)
harness
source in sensor signal circuit wiring
harness
Engine speed sensor: Open There is an open in the signal circuit • Defective engine speed sensor or
(KA) of the engine speed sensor and the defective adjustment
signal is not input • Open in sensor signal circuit wiring
DLE2KA
harness
(TM-70)
harness
Engine speed sensor: * See When the signal of the engine • Defective engine speed sensor
Contents (LC) speed sensor is less than 350 rpm, • Short circuit with chassis ground or
DLE2LC
the signal of the transmission input short circuit with power source in
(TM-71)
shaft speed sensor inputs more sensor signal circuit wiring harness
than 500 rpm • Defective transmission controller
Transmission input shaft There is an open in the signal circuit • Defective transmission input shaft
speed sensor: Open (KA) of the transmission input shaft speed sensor or defective adjustment
speed sensor and the signal is not • Open in sensor signal circuit wiring
DLF1KA
input harness
(TM-72)
harness
Transmission input shaft There is an abnormality in the • Defective transmission input shaft
speed sensor: * See Con- speed calculated from the engine speed sensor
tents (LC) speed sensor signal, transmission • Short circuit with chassis ground or
DLF1LC intermediate shaft speed sensor short circuit with power source in
(TM-73) signal, and output shaft R speed sensor signal circuit wiring harness
sensor signal, and the speed of the • Defective transmission controller
transmission input shaft sensor
signal
20-436 1 HM400-1L
12
Action
Code
• Sensor power source voltage • Fixes torque converter oil pressure • Excessive shock when lock-up is
TC-INT (2) - (1): 20 - 30 V to oil pressure set inside controller actuated
• Sensor signal voltage and carries out control
TC-INT (3) - (1): 0.8 - 2.0 V
E01
• Sensor resistance value • Takes no action • Fuel gauge does not give correct
T08 (male) (1) - (2): display
• When full: Max. 12 Ω
E01
• When empty: 74 - 100 Ω
• Sensor power source voltage • Carries out automatic shifting in • Transmission shock becomes
AS2 (1) - (3): 4.6 - 5.4 V normal mode (but controls with excessive
• Sensor signal voltage clutch oil pressure taken as engine • Immediately shifts up when traveling
• AS3 (2) - (3): at full throttle) downhill
• Lo position: 1.0 - 1.4 V
• Hi position: 3.6 - 4.0 V
E03
• Sensor resistance value • Holds speed range during travel • Cannot shift gear
EREV (male) (1) - (2): 500 - 1000 • When gearshift lever is returned to • If gearshift lever is returned to N,
Ω N, holds in Neutral machine cannot move off again until
it is stopped E03
• Tachometer does not work (displays
0 rpm)
EREV (male) (1) - (2): 500 - 1000 • When gearshift lever is returned to • If gearshift lever is returned to N,
Ω N, holds in Neutral machine cannot move off again until E03
it is stopped
• Tach. does not go above 350 rpm
• Sensor resistance value • Holds speed range during travel • Lock-up is canceled and
N1 (male) (1) - (2): 500 - 1000 Ω and turns actuation of lock-up OFF transmission cannot be shifted
N, holds in Neutral machine cannot move off again until E03
it is stopped
• Sensor resistance value • Holds speed range during travel • Lock-up is canceled and
N1 (male) (1) - (2): 500 - 1000 Ω and turns actuation of lock-up OFF transmission cannot be shifted
E03
it is stopped
HM400-1L 20-437 1
12
Transmission intermediate There is an open in the signal circuit • Defective transmission intermediate
shaft speed sensor: Open of the transmission intermediate shaft speed sensor or defective
(KA) shaft speed sensor and the signal is adjustment
DLF2KA not input • Open in sensor signal circuit wiring
(TM-74) harness
harness
Transmission intermediate There is an abnormality in the • Defective transmission intermediate
shaft speed sensor: * See speed calculated from the engine shaft speed sensor
Contents (LC) speed sensor signal, transmission • Short circuit with chassis ground or
DLF2LC
input shaft speed sensor signal, and short circuit with power source in
(TM-75)
output shaft R speed sensor signal, sensor signal circuit wiring harness
and the speed of the transmission • Defective transmission controller
intermediate shaft sensor signal
Transmission output shaft There is an open in the signal circuit • Defective transmission output shaft R
speed sensor: Open (KA) of the transmission output shaft R speed sensor or defective adjustment
speed sensor and the signal is not • Open in sensor signal circuit wiring
DLT3KA
input harness
(TM-76)
harness
Transmission output shaft There is an abnormality in the • Defective transmission output shaft R
speed sensor: * See Con- speed calculated from the engine speed sensor or defective adjustment
tents (LC) speed sensor signal, transmission • Short circuit with chassis ground or
DLT3LC input shaft speed sensor signal, and short circuit with power source in
(TM-77) intermediate shaft speed sensor sensor signal circuit wiring harness
signal, and the speed of the • Defective transmission controller
transmission output shaft R sensor • efective retarder controller
signal
Solenoid for inter-axle differ- No electric current flows when there • Defective differential lock clutch
ential lock: Open (KA) is output to the differential lock solenoid
clutch solenoid • Open in solenoid (+) circuit wiring
DXH0KA
harness
(TM-78)
harness
Solenoid for inter-axle differ- An extremely large electric current • Defective differential lock clutch
ential lock: Short circuit (KB) flows when there is output to the solenoid
differential lock clutch solenoid or • Short circuit, short circuit with chassis
DXH0KB
electric current flows when it is OFF ground, or short circuit with power
(TM-79)
source in solenoid (+) circuit wiring
harness
Solenoid for lock-up clutch: No electric current flows when there • Defective lock-up clutch solenoid
DXH1KA Open (KA) is output to the lock-up clutch • Open in solenoid (+) circuit
(TM-80) solenoid • Open in solenoid (-) circuit
Solenoid for lock-up clutch: An extremely large electric current • Defective lock-up clutch solenoid
Short circuit (KB) flows when there is output to the • Short circuit, with chassis ground, or
lock-up clutch solenoid or electric short circuit with power source in
DXH1KB current flows when it is OFF solenoid (+) circuit wiring harness
(TM-81) • Defective transmission controller
20-438 1 HM400-1L
12
Action
Code
N2 (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to • If gearshift lever is returned to N,
it is stopped
E03
it is stopped E03
• Sensor resistance value • Holds speed range during travel • Speedometer displays 0 km/h
N3 (male) (1) - (2): 500 - 1000 Ω • When gearshift lever is returned to • Cannot shift gear
N, holds in Neutral • If gearshift lever is returned to N,
machine cannot move off again until E03
it is stopped
it is stopped
E03
• Speedometer displays abnormal
speed
• Solenoid resistance value • Continues output as it is • Inter-axle differential lock does not
D/L-PS (male) (1) - (2): 5 - 15 Ω work
E01
D/L-PS (male) (1) - (2): 5 - 15 Ω command OFF work or is not canceled
E01
• Solenoid resistance value • Turns lock-up actuation OFF • Lock-up is not actuated
L/U-PS (male) (1) - (2): 5 - 15 Ω
E03
• Solenoid resistance value • Holds speed range during travel • Lock-up is always canceled or
L/U-PS (male) (1) - (2): 5 - 15 Ω and turns actuation of lock-up OFF always actuated and transmission
• When gearshift lever is returned to cannot be shifted
N, holds in Neutral • If gearshift lever is operated to N,
E03
machine cannot move off again until
it is stopped (depending on condition
of failure, machine may not be able
to move off again)
HM400-1L 20-439 1
12
Solenoid for Hi clutch: Open No electric current flows when there • Defective Hi clutch solenoid
(KA) is output to the Hi clutch solenoid • Open in solenoid (+) circuit
DXH2KA
• Open in solenoid (-) circuit
(TM-82)
Solenoid for Hi clutch: Short An extremely large electric current • Defective Hi clutch solenoid
circuit (KB) flows when there is output to the Hi • Short circuit, short circuit with chassis
clutch solenoid or electric current ground, or short circuit with power
DXH2KB flows when it is OFF source in solenoid (+) circuit wiring
(TM-83) harness
solenoid (-) circuit wiring harness
Solenoid for Lo clutch: Open No electric current flows when there • Defective Lo clutch solenoid
DXH3KA (KA) is output to the Lo clutch solenoid • Open in solenoid (+) circuit
(TM-84) • Open in solenoid (-) circuit
Solenoid for Lo clutch: Short An extremely large electric current • Defective Lo clutch solenoid
circuit (KB) flows when there is output to the Lo • Short circuit, short circuit with chassis
(TM-85) harness
Solenoid for 1st clutch: Open No electric current flows when there • Defective 1st clutch solenoid
DXH4KA (KA) is output to the 1st clutch solenoid • Open in solenoid (+) circuit
Solenoid for 1st clutch: Short An extremely large electric current • Defective 1st clutch solenoid
circuit (KB) flows when there is output to the 1st • Short circuit, short circuit with chassis
(TM-87) harness
Solenoid for 2nd clutch: No electric current flows when there • Defective 2nd clutch solenoid
DXH5KA Open (KA) is output to the 2nd clutch solenoid • Open in solenoid (+) circuit
Solenoid for 2nd clutch: An extremely large electric current • Defective 2nd clutch solenoid
Short circuit (KB) flows when there is output to the • Short circuit, short circuit with chassis
2nd clutch solenoid or electric ground, or short circuit with power
DXH5KB current flows when it is OFF source in solenoid (+) circuit wiring
(TM-89) harness
20-440 1 HM400-1L
12
Action
Code
• Solenoid resistance value • Shifts to Neutral during travel
H-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again E03
• Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
H-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
cannot move off again (depending
on condition of failure, machine may
E03
not be able to move off again)
L-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
cannot move off again
L-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
1-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
• Solenoid resistance value • Sets transmission to Neutral. Shifts to Neutral during travel
1-PS (male) (1) - (2): 5 - 15 Ω If travel is not stopped, machine
E03
E03
E03
HM400-1L 20-441 1
12
Solenoid for 3rd clutch: Open No electric current flows when there • Defective 3rd clutch solenoid
(KA) is output to the 3rd clutch solenoid • Open in solenoid (+) circuit
DXH6KA
• Open in solenoid (-) circuit
(TM-90)
Solenoid for 3rd clutch: Short An extremely large electric current • Defective 3rd clutch solenoid
circuit (KB) flows when there is output to the 3rd • Short circuit, short circuit with chassis
flows when it is OFF source in solenoid (+) circuit wiring
DXH6KB
harness
(TM-91)
Solenoid for R clutch: Open No electric current flows when there • Defective R clutch solenoid
DXH7KA (KA) is output to the R clutch solenoid • Open in solenoid (+) circuit
Solenoid for R clutch: Short An extremely large electric current • Defective R clutch solenoid
circuit (KB) flows when there is output to the R • Short circuit, short circuit with chassis
(TM-93) harness
20-442 1 HM400-1L
12)
Action
Code
Solenoid resistance value • Sets transmission to Neutral. • Shifts to Neutral during travel
cannot move off again E03
not be able to move off again) E03
R-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
R-PS (male) (1) - (2): 5 - 15 Ω • If travel is not stopped, machine
E03
HM400-1L 20-443 1
12
• Failure.

Your
or Voltage Your
information
2. Diode Test
Your
resistance or Voltage Your
information
Your
ground or within
or Voltage Your
harness Test procedure for harness. (connector) to (connector) readings 7
information
Resistance Ω Your
20-444 1 HM400-1L
• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.
HM400-1L 20-445 1
TROUBLESHOOTING (TM-1) FAILURE CODE [1380MW]
12
(TM-1) FAILURE CODE [1380MW]
LOCK-UP CLUTCH SLIPPING (MW)

• Lock-up clutch slipping.
Contents Of Trouble
• TM code 1 displayed.

Steps Circuit Diagnostic Procedures For Failure Code [1380MW] Specifications No. Readings
1. L/U Clutch ECMV Solenoid And Switch
• Disconnect (L/U-PS) connector from solenoid and isolate solenoid.
• Disconnect (L/U-SW) connector from switch and isolate switch.
At solenoid L/U-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L/U-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L/U-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
and system operating
• Disconnect (L/U-PS and L/U-SW) connectors from solenoid and switch, isolate connectors.
• Disconnect (ATC2 and ATC5A) connector from the transmission controller and install T-adapter on (ATC2 and ATC5A) wiring harness
connector only.
Between connectors L/U-PS, (1) and ATC2, (10) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L/U-PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Between connectors L/U-SW, (1) and ATC5A, (11) 0.0 to 1.0Ω 6
At connector L/U-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L/U-PS, between (2) and chassis ground. (OL) open 8
harness At connector L/U-PS, between (1) and (2) (OL) open 9
At connector L/U-SW, between (1) and chassis ground. (OL) open 10
3. Transmission Controller Unit
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Controller Unit.
20-446 1 HM400-1L
TROUBLESHOOTING (TM-1) FAILURE CODE [1380MW]
HM400-1L 20-447 1
TROUBLESHOOTING (TM-2) FAILURE CODE [1500LO]
12
(TM-2) FAILURE CODE [1500LO]
TRANSMISSION CLUTCH (LO)

★ If testing for failure code [1380MW] has indicated no problems with solenoid, switch and wiring, proceed to testing for
mechanical failure in transmission hydraulic system.
Cause Remedy
With ignition switch in Is other failure code [15*8l1] also

the “ON” position. Other problem occurring at the
displayed or recorded at same YES Replace
same time
time?
NO
Does condition become normal Replace

Turn ignition switch to
when transmission controller is NO Defective hydraulic mechanical
the “ON” position.
replaced? system
YES
Defective transmission controller Replace
20-448 1 HM400-1L
TROUBLESHOOTING (TM-3) FAILURE CODE [15BONX]
(TM-3) FAILURE CODE [15BONX]
TRANSMISSION OIL FILTER INDICATING A CLOGGED CONDITION (NX)

• Transmission filter may be clogged.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15BONX] Specifications No. Readings
Transmission Filter ⎯ Replace transmission filter and fluid System OK? 1 Yes or No
1. Clog Switch Unit
• Disconnect (T03) connector from clog switch and isolate switch.
At switch TO3, between (1) and (2) (OL) open 2
A. Switch test Resistance Ω
At switch TO3, between (1) or (2) and chassis ground. (OL) open 3
• Disconnect (TO3) connector from switch and isolate connector.
• Disconnect (ATC5A) connector from transmission controller and install T-adapter on (ATC5A) wiring harness connector only.
A. Open or high Between connectors ATC5A, (6) and TO3, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors TO3, (2) and chassis ground. 0.0 to 1.0Ω 5
B. Short to chassis At connector TO3, between (1) and chassis ground. (OL) open 6
harness At connector TO3, between (1) and (2) (OL) open 7

Remark
HM400-1L 20-449 1
TROUBLESHOOTING (TM-3) FAILURE CODE [15BONX]
20-450 1 HM400-1L
TROUBLESHOOTING (TM-4) FAILURE CODE [15GOMW]
(TM-4) FAILURE CODE [15GOMW]
“R” CLUTCH SLIPPING (MW)

• Reverse clutch slipping.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15GOMW] Specifications No. Readings
1. “R” Clutch ECMV Solenoid And Switch
• Disconnect (R-PS) connector from solenoid and isolate solenoid.
• Disconnect (R-SW) connector from switch and isolate switch.
At solenoid R-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch R-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch R-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
• Disconnect (R-PS and R-SW) connectors from solenoid and switch, isolate connectors.
connector only.
Between connectors R-PS, (1) and ATC2, (5) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors R-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors R-SW, (1) and ATC5A, (16) 0.0 to 1.0Ω 6
At connector R-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector R-PS, between (2) and chassis ground. (OL) open 8
harness At connector R-PS, between (1) and (2) (OL) open 9
At connector R-SW, between (1) and chassis ground. (OL) open 10
Remark
HM400-1L 20-451 1
TROUBLESHOOTING (TM-4) FAILURE CODE [15GOMW]
20-452 1 HM400-1L
TROUBLESHOOTING (TM-5) FAILURE CODE [15HOMW]
(TM-5) FAILURE CODE [15HOMW]
“HI” CLUTCH SLIPPING (MW)

• High clutch slipping.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15HOMW] Specifications No. Readings
1. “HI” Clutch ECMV Solenoid And Switch
• Disconnect (H-PS) connector from solenoid and isolate solenoid.
• Disconnect (H-SW) connector from switch and isolate switch.
At solenoid H-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch H-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch H-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
• Disconnect (H-PS and H-SW) connectors from solenoid and switch, isolate connectors.
connector only.
Between connectors H-PS, (1) and ATC2, (4) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors H-PS, (2) and ATC2, (15) 0.0 to 1.0Ω 5
resistance
Between connectors H-SW, (1) and ATC5A, (12) 0.0 to 1.0Ω 6
At connector H-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector H-PS, between (2) and chassis ground. (OL) open 8
harness At connector H-PS, between (1) and (2) (OL) open 9
At connector H-SW, between (1) and chassis ground. (OL) open 10
Remark
HM400-1L 20-453 1
TROUBLESHOOTING (TM-5) FAILURE CODE [15HOMW]
20-454 1 HM400-1L
TROUBLESHOOTING (TM-6) FAILURE CODE [15JOMW]
(TM-6) FAILURE CODE [15JOMW]
“LO” CLUTCH SLIPPING (MW)

• Low clutch slipping.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15JOMW] Specifications No. Readings
1. “Lo” Clutch ECMV Solenoid And Switch
• Disconnect (L-PS) connector from solenoid and isolate solenoid.
• Disconnect (L-SW) connector from switch and isolate switch.
At solenoid L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch L-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
• Disconnect (L-PS and L-SW) connectors from solenoid and switch, isolate connectors.
connector only.
Between connectors L-PS, (1) and ATC2, (7) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors L-PS, (2) and ATC2, (17) 0.0 to 1.0Ω 5
resistance
Between connectors L-SW, (1) and ATC5A, (10) 0.0 to 1.0Ω 6
At connector L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector L-PS, between (2) and chassis ground. (OL) open 8
harness At connector L-PS, between (1) and (2) (OL) open 9
At connector L-SW, between (1) and chassis ground. (OL) open 10
Remark
HM400-1L 20-455 1
TROUBLESHOOTING (TM-6) FAILURE CODE [15JOMW]
20-456 1 HM400-1L
TROUBLESHOOTING (TM-7) FAILURE CODE [15KOMW]
(TM-7) FAILURE CODE [15KOMW]
1ST CLUTCH SLIPPING (MW)

• 1st clutch slipping.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15KOMW] Specifications No. Readings
1. 1st Clutch ECMV Solenoid And Switch
• Disconnect (1-PS) connector from solenoid and isolate solenoid.
• Disconnect (1-SW) connector from switch and isolate switch.
At solenoid 1-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch 1-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch 1-SW, between (1) and (2) engine running and
0.0 to 1.0Ω 3
system operating.
• Disconnect (1-PS and 1-SW) connectors from solenoid and switch, isolate connectors.
connector only.
Between connectors 1-PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors 1-PS, (2) and ATC2, (13) 0.0 to 1.0Ω 5
resistance
Between connectors 1-SW, (1) and ATC5A, (13) 0.0 to 1.0Ω 6
At connector 1-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector 1-PS, between (2) and chassis ground. (OL) open 8
harness At connector 1-PS, between (1) and (2) (OL) open 9
At connector 1-SW, between (1) and chassis ground. (OL) open 10
Remark
HM400-1L 20-457 1
TROUBLESHOOTING (TM-7) FAILURE CODE [15KOMW]
20-458 1 HM400-1L
TROUBLESHOOTING (TM-8) FAILURE CODE [15LOMW]
(TM-8) FAILURE CODE [15LOMW]
2ND CLUTCH SLIPPING (MW)

• 2nd clutch slipping.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15LOMW] Specifications No. Readings
1. 2nd Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-459 1
TROUBLESHOOTING (TM-8) FAILURE CODE [15LOMW]
20-460 1 HM400-1L
TROUBLESHOOTING (TM-9) FAILURE CODE [15MOMW]
(TM-9) FAILURE CODE [15MOMW]
3RD CLUTCH SLIPPING (MW)

• 3rd clutch slipping.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15MOMW] Specifications No. Readings
1. 3rd Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-461 1
TROUBLESHOOTING (TM-9) FAILURE CODE [15MOMW]
20-462 1 HM400-1L
TROUBLESHOOTING (TM-10) FAILURE CODE [15SBL1]
(TM-10) FAILURE CODE [15SBL1]
ECMV FOR “R” CLUTCH NOT DISENGAGING (L1)

• Reverse clutch not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SBL1] Specifications No. Readings
1. R Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-463 1
TROUBLESHOOTING (TM-10) FAILURE CODE [15SBL1]
20-464 1 HM400-1L
TROUBLESHOOTING (TM-11) FAILURE CODE [15SBMA]
(TM-11) FAILURE CODE [15SBMA]
ECMV FOR “R” CLUTCH NOT ENGAGING (MA)

• Reverse clutch not engaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SBMA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-465 1
TROUBLESHOOTING (TM-11) FAILURE CODE [15SBMA]
20-466 1 HM400-1L
TROUBLESHOOTING (TM-12) FAILURE CODE [15SCL1]
(TM-12) FAILURE CODE [15SCL1]
ECMV “HI” CLUTCH NOT DISENGAGING (L1)

• High clutch not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SCL1] Specifications No. Readings
1. Hi Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-467 1
TROUBLESHOOTING (TM-12) FAILURE CODE [15SCL1]
20-468 1 HM400-1L
TROUBLESHOOTING (TM-13) FAILURE CODE [15SCMA]
(TM-13) FAILURE CODE [15SCMA]
ECMV “HI” CLUTCH NOT DISENGAGING (MA)

• Hi clutch not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SCMA] Specifications No. Readings
1. HI Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-469 1
TROUBLESHOOTING (TM-13) FAILURE CODE [15SCMA]
20-470 1 HM400-1L
TROUBLESHOOTING (TM-14) FAILURE CODE [15SDL1]
(TM-14) FAILURE CODE [15SDL1]
ECMV “LO” CLUTCH NOT DISENGAGING (L1)

• Low clutch is not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SDL1] Specifications No. Readings
1. Lo Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-471 1
TROUBLESHOOTING (TM-14) FAILURE CODE [15SDL1]
20-472 1 HM400-1L
TROUBLESHOOTING (TM-15) FAILURE CODE [15SDMA]
(TM-15) FAILURE CODE [15SDMA]
ECMV “LO” CLUTCH NOT ENGAGING (MA)

• Low clutch not engaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SDMA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-473 1
TROUBLESHOOTING (TM-15) FAILURE CODE [15SDMA]
20-474 1 HM400-1L
TROUBLESHOOTING (TM-16) FAILURE CODE [15SEL1]
(TM-16) FAILURE CODE [15SEL1]
ECMV “1ST” CLUTCH NOT DISENGAGING (L1)

• 1st clutch system not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SEL1] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.system operating.
connector only.
Between connectors1 -PS, (1) and ATC2, (2) 0.0 to 1.0Ω 4
A. Open or high
resistance
Remark
HM400-1L 20-475 1
TROUBLESHOOTING (TM-16) FAILURE CODE [15SEL1]
20-476 1 HM400-1L
TROUBLESHOOTING (TM-17) FAILURE CODE [15SEMA]
(TM-17) FAILURE CODE [15SEMA]
ECMV “1ST” CLUTCH NOT ENGAGING (MA)

• 1st clutch not engaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SEMA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-477 1
TROUBLESHOOTING (TM-17) FAILURE CODE [15SEMA]
20-478 1 HM400-1L
TROUBLESHOOTING (TM-18) FAILURE CODE [15SFL1]
(TM-18) FAILURE CODE [15SFL1]
ECMV “2ND” CLUTCH NOT DISENGAGING (L1)

• 2nd clutch not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SFL1] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-479 1
TROUBLESHOOTING (TM-18) FAILURE CODE [15SFL1]
20-480 1 HM400-1L
TROUBLESHOOTING (TM-19) FAILURE CODE [15SFMA]
(TM-19) FAILURE CODE [15SFMA]
ECMV “2ND” CLUTCH NOT ENGAGING (MA)

• 2nd clutch not engaging
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SFMA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-481 1
TROUBLESHOOTING (TM-19) FAILURE CODE [15SFMA]
20-482 1 HM400-1L
TROUBLESHOOTING (TM-20) FAILURE CODE [15SGL1]
(TM-20) FAILURE CODE [15SGL1]
ECMV “3RD” CLUTCH NOT DISENGAGING (L1)

• 3rd clutch not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SGL1] Specifications No. Readings
• Disconnect (-PS) connector from solenoid and isolate solenoid.
• Disconnect (-SW) connector from switch and isolate switch.
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-483 1
TROUBLESHOOTING (TM-20) FAILURE CODE [15SGL1]
20-484 1 HM400-1L
TROUBLESHOOTING (TM-21) FAILURE CODE [15SGMA]
(TM-21) FAILURE CODE [15SGMA]
ECMV “3RD” CLUTCH NOT ENGAGING (MA)

• 3rd clutch not engaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SGMA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-485 1
TROUBLESHOOTING (TM-21) FAILURE CODE [15SGMA]
20-486 1 HM400-1L
TROUBLESHOOTING (TM-22) FAILURE CODE [15SJL1]
(TM-22) FAILURE CODE [15SJL1]
ECMV “LOCK-UP” CLUTCH NOT DISENGAGING (L1)

• Lock-up clutch not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SJL1] Specifications No. Readings
1. Lock-up Clutch ECMV Solenoid And Switch
• Disconnect (L-U-SW) connector from switch and isolate switch.
Resistance Ω
test
0.0 to 1.0Ω 3
and system operating.
connector only.
A. Open or high
Resistance Ω Between connectors L/U -PS, (2) and ATC2, (20) 0.0 to 1.0Ω 5
resistance
Remark
HM400-1L 20-487 1
TROUBLESHOOTING (TM-22) FAILURE CODE [15SJL1]
20-488 1 HM400-1L
TROUBLESHOOTING (TM-23) FAILURE CODE [15SJMA]
(TM-23) FAILURE CODE [15SJMA]
ECMV “LOCK-UP” CLUTCH NOT ENGAGING (MA)

• Lock-up clutch not engaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SJMA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-489 1
TROUBLESHOOTING (TM-23) FAILURE CODE [15SJMA]
20-490 1 HM400-1L
TROUBLESHOOTING (TM-24) FAILURE CODE [15SKL1]
(TM-24) FAILURE CODE [15SKL1]
ECMV “INTER-AXLE” CLUTCH NOT DISENGAGING (L1)

• Inter-axle not disengaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SKL1] Specifications No. Readings
1. Inter-axle Clutch ECMV Solenoid And Switch
• Disconnect (D/L-PS) connector from solenoid and isolate solenoid.
• Disconnect (D/L-SW) connector from switch and isolate switch.
At solenoid D/L-PS, between (1) and (2) 5 to 15Ω 1
A. Solenoid and switch At switch D/L-SW, between (1) and (2) (OL) open 2
Resistance Ω
test
At switch D/L-SW, between (1) and (2) engine running
0.0 to 1.0Ω 3
• Disconnect (D/L-PS and D/L-SW) connectors from solenoid and switch, isolate connectors.
connector only.
Between connectors D/L-PS, (1) and ATC2, (8) 0.0 to 1.0Ω 4
A. Open or high
Resistance Ω Between connectors D/L-PS, (2) and ATC2, (18) 0.0 to 1.0Ω 5
resistance
Between connectors D/L-SW, (1) and ATC5A, (17) 0.0 to 1.0Ω 6
At connector D/L-PS, between (1) and chassis ground. (OL) open 7
B. Short to chassis At connector D/L-PS, between (2) and chassis ground. (OL) open 8
harness At connector D/L-PS, between (1) and (2) (OL) open 9
At connector D/L-SW, between (1) and chassis ground. (OL) open 10
Remark
HM400-1L 20-491 1
TROUBLESHOOTING (TM-24) FAILURE CODE [15SKL1]
20-492 1 HM400-1L
TROUBLESHOOTING (TM-25) FAILURE CODE [15SKMA]
(TM-25) FAILURE CODE [15SKMA]
ECMV “INTER-AXLE” CLUTCH NOT ENGAGING (MA)

• Inter-axle not engaging.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [15SKMA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-493 1
TROUBLESHOOTING (TM-25) FAILURE CODE [15SKMA]
20-494 1 HM400-1L
TROUBLESHOOTING (TM-26) FAILURE CODE [2B61MW]
(TM-26) FAILURE CODE [2B61MW]
ECMV “INTER-AXLE” CLUTCH SLIPPING (MW)

• Inter-axle possibly slipping.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [2B61MW] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
HM400-1L 20-495 1
TROUBLESHOOTING (TM-26) FAILURE CODE [2B61MW]
20-496 1 HM400-1L
TROUBLESHOOTING (TM-27) FAILURE CODE [2F00KM]
(TM-27) FAILURE CODE [2F00KM]
PARKING BRAKE SYSTEM INDICATING FAILURE (KM)

• Parking brake system may be defective.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [2F00KM] Specifications No. Readings
Fuse Check ⎯ Check to see if fuse (BT3-16) is blown ⎯ 1 Yes or No
1. Parking Brake Switch
• Disconnect (B17) connector from switch and isolate switch.
At switch B17, between (1) and (2)
(OL) open 2
parking brake “OFF” position.
At switch B17, between (1) and (2)
0.0 to 1.0Ω 3
parking brake “ON” position.
2. Parking Brake Relay
• Replace relay (R03) with known good relay.
• Turn ignition switch to the “ON” position.
A. Relay check ⎯ Is failure code [2F00KM] gone? ⎯ 4 Yes or No
• Disconnect (B17) connector from switch and isolate connector.
• Disconnect (R03) relay and isolate connector.
• Disconnect (BRC5A) connector from the transmission controller and install T-adapter on (BRC5A) wiring harness connector only.
• ✸ Turn ignition switch to the “ON” position and start the engine for this test.
Between connection B17, (1) and chassis ground, fuse
(OL) open 5
A. Short to removed.
chassis ground Resistance Ω
Between connection B17, (2) and chassis ground. (OL) open 6
or within harness
At connection B17, between (1) and (2) (OL) open 7
Voltage ✸ Between connection B17, (1) and chassis ground. 20 to 30V 8
B. Open or high Between connection B17, (2) and R03, (1) 0.0 to 1.0Ω 9
resistance Resistance Ω At connection R03, (2) and (6) and chassis ground. 0.0 to 1.0Ω 10
Between connection R03, (3) and BRC5A, (5) 0.0 to 1.0Ω 11
Remark
HM400-1L 20-497 1
TROUBLESHOOTING (TM-27) FAILURE CODE [2F00KM]
20-498 1 HM400-1L
TROUBLESHOOTING (TM-28) FAILURE CODE [6014NX]
(TM-28) FAILURE CODE [6014NX]
HYDRAULUC TANK FILTER CLOGGED (NX)

• Hydraulic tank filter may be clogged.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [6014NX] Specifications No. Readings
Hydraulic Tank Filter ⎯ Check or replace hydraulic tank filter System OK? 1 Yes or No
1. Hydraulic Tank Filter Switch
• Disconnect (T05) connector from switch and isolate switch.
A. Switch test Resistance Ω At switch T05, between (1) and (2) 0.0 to 1.0Ω 2
• Disconnect (T05) connector from switch and isolate connector.
• Disconnect (ATC5A) connector from transmission controller and install T-adapter on (ATC5A) wiring harness connector only.
A. Short to Between connector T05, (1) and chassis ground. (OL) open 3
or within harness At connector T05, between (1) and (2) (OL) open 4
B. Open or high Between connectors T05, (1) and ATC5A, (9) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connector T05, (2) and chassis ground. 0.0 to 1.0Ω 6
Remark
HM400-1L 20-499 1
TROUBLESHOOTING (TM-28) FAILURE CODE [6014NX]
20-500 1 HM400-1L
TROUBLESHOOTING (TM-29) FAILURE CODE [989A00]
12
(TM-29) FAILURE CODE [989A00]
POSSIBLE ENGINE OVER SPEED CONDITION (00)

TM Code Failure Code Controller Code
Trouble Possible engine over speed
29 989A00 TM
Description of • Did machine travel with transmission input shaft speed at more than 2450 RPM?
Trouble
Yes -Operator over speed machine while traveling, check condition of engine and transmission for damage.
No -Defective transmission controller (see remedy below)
Remedy • Operate a short time and watch condition
Related circuit diagram (None)
HM400-1L 20-501 1
TROUBLESHOOTING (TM-30) FAILURE CODE [989AKZ]
(TM-30) FAILURE CODE [989AKZ]
OPEN OR SHORT IN ENGINE OVER SPEED COMMAND SIGNAL (KZ)

• Engine over speed signal possibly defective
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [989AKZ] Specifications No. Readings
• Disconnect (BRC1, BRC2, BRC5B) connector from retarder controller and install T-adapter between (BRC1, BRC2, BRC5B) wiring harness
connector and controller.
• Disconnect (ATC1) connector from transmission controller and install T-adapter between (ATC1) wiring harness connector and controller.
✸ At connector ATC1, (13) and chassis ground. 0.7 to 5.0V 1
✸ At connector ATC1, (7) and chassis ground. 20 to 30V 2
✸ At connector ATC1, (9), (17) and chassis ground, igni-
Voltage 20 to 30V 3
tion key in the ON position.
A. Open or high ✸ At connector BRC1, (17) and chassis ground. 20 to 30V 4

resistance ✸ At connector BRC2, (1) and chassis ground. 20 to 30V 5
Between connectors ATC1, (13) and BRC5B, (5) 0.0 to 1.0Ω 6
At connector ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 7
Resistance Ω
At connector BRC1, (16) and chassis ground. 0.0 to 1.0Ω 8
At connector BRC2, (21) and chassis ground. 0.0 to 1.0Ω 9
B. Short to With controllers (BRC5B and ATC1) disconnected from
chassis ground Resistance Ω wiring harness between connections BRC5B, (5) and (OL) open 10
or within harness chassis ground.
2. Transmission Or Retarder Controller Units
• No testing procedure for the controllers.
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission or Retarder
20-502 1 HM400-1L
TROUBLESHOOTING (TM-30) FAILURE CODE [989AKZ]
HM400-1L 20-503 1
TROUBLESHOOTING (TM-31)FAILURE CODE [989D00]
(TM-31)FAILURE CODE [989D00]
REAR OVERTURN SIGNAL OUT OF RANGE (00)

• Rear overturn signal possibly out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [989D00] Specifications No. Readings
Was dump operations carried out on slope of more than
Inclination Of Machine ⎯ 15o max. 1 Yes or No
15o
1. Inclination Sensor
• Disconnect (T10) connector from inoculation sensor and isolate sensor.
• Park machine on a level surface.
At sensor T10, between (1) and (3) 2
A. Switch test Resistance Ω At sensor T10, between (2) and (3) 3
• Disconnect (T10) connector from sensor and isolate connector.
• Disconnect (ATC2, ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC2, ATC3A and ATC3B) wiring
harness connector only
• ✸ For this test the ignition key must be in the “ON” position.
✸ At controller ATC2, between (1) and chassis
Voltage 12V 5
ground.
At controller ATC3A, between (16) and chassis
0.0 to 1.0Ω 6
A. Open or high ground.
resistance
Resistance Ω Between connections T10, (1) and ATC2, (14) 0.0 to 1.0Ω 7
Between connections T10, (2) and ATC3A, (16) 0.0 to 1.0Ω 8
Between connections T10, (3) and ATC3B, (16) 0.0 to 1.0Ω 9
At connector T10, between (1) and chassis ground. (OL) open 10
B. Short to At connector T10, between (3) and chassis ground. (OL) open 12
At connector T10, between (1) and (3) (OL) open 14
Remark
20-504 1 HM400-1L
TROUBLESHOOTING (TM-31)FAILURE CODE [989D00]
HM400-1L 20-505 1
TROUBLESHOOTING (TM-32)FAILURE CODE [AA10NX]
(TM-32)FAILURE CODE [AA10NX]
AIR CLEANER CLOGG INDICATION (NX)

• Possible air cleaner clog incorrect indication.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [AA10NX] Specifications No. Readings
Air Cleaner ⎯ Check condition of air cleaner Air cleaner OK? 1 Yes or No
Fuse Check ⎯ Check condition of fuse (BT3-14) Fuse OK? 2 Yes or No
1. Air Cleaner Switch
• Disconnect (T11) connector from air cleaner and isolate air cleaner switch.
At switch T11, between (1) and (2) 0.0 to 1.0Ω 3
At switch T11, between (1) or (2) and chassis ground. (OL) open 4
2. Dust Indicator Relay
A. Relay check ⎯ Is failure code [AA10NX] gone? ⎯ 5 Yes or No
• Disconnect (T11) connector from air cleaner switch.
• Disconnect (ATC3A) connector from transmission controller and install T-adapter on (ATC3A) wiring harness connector only
Voltage ✸ At connector R32, between (1) and chassis ground. 20 to 30V 6
Between connectors T11, (1) and R32, (2) 0.0 to 1.0Ω 7
A. Open or high
Between connectors T11, (2) and chassis ground. 0.0 to 1.0Ω 8
Between connectors R32, (3) and ATC3A, (19)l 0.0 to 1.0Ω 9
Between connectors R32, (6) and ATC3A, (16)l 0.0 to 1.0Ω 10
B. Short to At connector ATC3A, between (16) and chassis
(OL) open 13
chassis ground Resistance Ω ground.
or within harness
At connector ATC3A, between (19) and chassis
(OL) open 14
ground.
At connector ATC3A, between (16) and (19) (OL) open 15

Remark
20-506 1 HM400-1L
TROUBLESHOOTING (TM-32)FAILURE CODE [AA10NX]
HM400-1L 20-507 1
TROUBLESHOOTING (TM-33) FAILURE CODE [AB00MA]
(TM-33) FAILURE CODE [AB00MA]
ALTERNATOR NOT CHARGING PROPERLY (MA)

• Charging system may be defective.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [AB00MA] Specifications No. Readings
1. Alternator Check
• Disconnect (DT1) connector from alternator and insert T-adaptor between (DT1) and alternator connector.
• Start the engine and run at mid speed.
At connector DT1, between (3) and chassis ground. 20 to 30V 1
Between alternator terminals (B) and (E) 20 to 30V 2
A. Alternator test Voltage
With engine OFF, and ignition switch in the “ON”
position between alternator terminal (B) and 20 to 30V 3
chassis ground.
• Disconnect (DT1) connector from alternator.
• Disconnect (ATC3B) connector from transmission controller and install T-adapter on (ATC3B) wiring harness connector only
A. Short to
chassis ground Resistance Ω At connector DT1, between (3) and chassis ground. (OL) open 4
or within harness
B. Open or high
Resistance Ω Between connectors DT1, (3) and ATC3B, (1) 0.0 to 1.0Ω 5
resistance
Remark
20-508 1 HM400-1L
TROUBLESHOOTING (TM-34) FAILURE CODE [B@BCZK]
(TM-34) FAILURE CODE [B@BCZK]
COOLANT LEVEL INDICATING A LOW LEVEL CONDITION (ZK)

• Coolant level possibly low.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [B@BCZK] Specifications Readings
Code
Check condition of coolant level first.
Coolant Level ⎯ [B@BCZK] 1 Yes or No
Add if necessary
gone?
1. Coolant Level Switch
• Disconnect (T01) from level switch.
At switch T01, between (1) and (2) coolant full 0.0 to 1.0Ω 2
At switch T01, between (1) or (2) and chassis ground. (OL) open 3
• Disconnect (T01) connector from level switch.
A. Open or high Between connectors T01, (2) and chassis ground. 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors T01, (1) and ATC5A, (3) 0.0 to 1.0Ω 5

Remark
HM400-1L 20-509 1
TROUBLESHOOTING (TM-34) FAILURE CODE [B@BCZK]
20-510 1 HM400-1L
TROUBLESHOOTING (TM-35) FAILURE CODE [B@HAZK]
(TM-35) FAILURE CODE [B@HAZK]
LOW HYDRAULIC TANK OIL LEVEL INDICATED (ZK)

• Possible hydraulic tank low oil level indicated.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [B@HAZK] Specifications No. Readings
1. Level Indicator Switch
• Disconnect (T06) from level switch.
A. Switch test Resistance Ω At switch T06, between (1) and chassis ground. 0.0 to 1.0Ω 1
• Disconnect (T06) connector from level switch.
A. Short to
chassis ground Resistance Ω Between connector T06, (1) and chassis ground. (OL) open 2
or within harness
B. Open or high
Resistance Ω Between connectors T06, (1) and ATC5A, (2) 0.0 to 1.0Ω 3
resistance
Remark
HM400-1L 20-511 1
TROUBLESHOOTING (TM-36) FAILURE CODE [B@JANS]
(TM-36) FAILURE CODE [B@JANS]
STEERING OIL OVERHEAT CONDITION INDICATED (ZK)

• Steering overheat condition indicated.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [B@JANS] Specifications No. Readings
Oil Temperature Check ⎯ Is the steering oil temperature over 123oC (253oF) ⎯ 1 Yes or No
1. Temperature Indicator Switch
• Disconnect (T04) from temperature switch.
A. Switch test Resistance Ω At switch T04, between (1) and chassis ground. 0.0 to 1.0Ω 2
• Disconnect (T04) connector from temperature switch.
A. Short to
or within harness
B. Open or high
Resistance Ω Between connectors T01, (1) and ATC3A, (11) 0.0 to 1.0Ω 4
resistance
Remark
20-512 1 HM400-1L
TROUBLESHOOTING (TM-37) FAILURE CODE [D1B0KZ]
(TM-37) FAILURE CODE [D1B0KZ]
POSSIBLE SHORT OR OPEN IN TRANSMISSION CUT RELAY SYSTEM (KZ)

• Short in transmission cut-off relay circuit
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [D1B0KZ] Specifications No. Readings
1. Relay Check
• Disconnect (R15) relay and install a known good relay.
Did code [D1B0KZ] disappear and is system working
A. Relay test ⎯ ⎯ 2 Yes or No
normal?
• Disconnect (ATC1 and ATC2) connector from transmission controller and install T-adapter on (ATC1 and ATC2) wiring harness connector only
✸ Between connector R15, (3) and chassis ground. 20 to 30V 3
Voltage
✸ Between connector ATC1, (17) and chassis ground. 20 to 30V 5
A. Open or high ✸ Between connector ATC1, (9) and chassis ground. 20 to 30V 6
resistance Between connectors R15, (1) and ATC1, (15) 0.0 to 1.0Ω 7
Between connectors R15, (5) and ATC2, (12) 0.0 to 1.0Ω 8
Resistance Ω
Between connector ATC1, (16) and chassis ground. 0.0 to 1.0Ω 9
B. Short to Between connector ATC2, (12) and chassis ground. (OL) open 11
or within harness Between connector ATC1, (15) and chassis ground. (OL) open 12

Remark
HM400-1L 20-513 1
TROUBLESHOOTING (TM-37) FAILURE CODE [D1B0KZ]
20-514 1 HM400-1L
TROUBLESHOOTING (TM-38) FAILURE CODE [D5ZBKX]
(TM-38) FAILURE CODE [D5ZBKX]
DEFFERENTIAL LOCK CIRCUIT SIGNIAL INCORRECT (KX)

• Differential lock signal possibly defective
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [D5ZBKX] Specifications No. Readings
1. Retarder Controller
• Disconnect (ATC3A) connector from transmission controller and install T-adapter between (ATC3A) connector and transmission controller.
A. Controller test Voltage At connection ATC3A, between (3) and (18) 0.5 to 5.0V 1
• Disconnect (BRC1, BRC2) connector from retarder controller and install T-adapter between (BRC1, BRC2) wiring harness connector
and controller.
• Disconnect (ATC1, ATC2, ATC3A) connector from transmission controller and install T-adapter between (ATC1, ATC2, ATC3A) wiring
harness connector and controller.
✸ At connector ATC3A, between (8) and (18) 0.7 to 5.0V 2
✸ Between connector ATC3A, (8) and chassis ground. 0.7 to 5.0V 3
✸ Between connector ATC1, (9), (17) and chassis
20 to 30V 5
ground, ignition switch ON
Voltage ✸ Between connector ATC2, (1), (12) and chassis

20 to 30V 6
✸ Between connector BRC1, (7) and chassis ground. 20 to 30V 7
A. Open or high ✸ Between connector BRC1, (9), (17) and chassis

20 to 30V 8
resistance ground, ignition switch ON
✸ Between connector BRC2, (1), (12) and chassis
20 to 30V 9
Between ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 10
Between ATC2, (21) and chassis ground. 0.0 to 1.0Ω 11
Between ATC3A, (18), (16) and chassis ground. 0.0 to 1.0Ω 12
Resistance Ω
Between BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 13
Between BRC2, (21) and chassis ground. 0.0 to 1.0Ω 14
Between connections BRC2, (6) and ATC3A, (8) 0.0 to 1.0Ω 15
B. Short to
chassis ground Resistance Ω Between connections BRC2, (6) and chassis ground. (OL) open 16
or within harness
3. Transmission Or Retarder Controller Unit
Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Transmission Or Rertarder
HM400-1L 20-515 1
TROUBLESHOOTING (TM-38) FAILURE CODE [D5ZBKX]
20-516 1 HM400-1L
TROUBLESHOOTING (TM-39) FAILURE CODE [D5ZCKZ]
(TM-39) FAILURE CODE [D5ZCKZ]
OPEN OR SHORT IN EXHAUST BRAKE COMMAND SIGNAL (KZ)

• Possibly open or short in communications between exhaust brake and transmission controller
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [D5ZCKZ] Specifications No. Readings
• Disconnect (BRC1, BRC2, BRC5B) connector from retarder controller and install T-adapter between (BRC1, BRC2, BRC5B) wiring harness
connector and controller.
• Disconnect (ATC1, ATC2) connector from transmission controller and install T-adapter between (ATC1, ATC2) wiring harness connector and
controller.
✸ At connector ATC1, (14) and chassis ground. less than 1V 1
✸ At connector ATC1, (7) and chassis ground. 20 to 30V 2
✸ At connector BRC1, (7) and chassis ground. 20 to 30V 3
20 to 30V 4
tion switch ON
Voltage
20 to 30V 5
tion switch ON
A. Open or high ✸ At connector BRC1, (9), (17) and chassis ground, igni-
20 to 30V 6
resistance tion switch ON
20 to 30V 7
tion switch ON
Between connector ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 8
Resistance Ω Between connector BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 10
Between connector BRC2, (21) and chassis ground. 0.0 to 1.0Ω 11
Between connections BRC5B, (4) and ATC1, (14) 0.0 to 1.0Ω 12
B. Short to With controllers (BRC5B and ATC1) disconnected from
chassis ground Resistance Ω wiring harness between connections BRC5B, (4) and (OL) open 13
or within harness chassis ground.
Remark
HM400-1L 20-517 1
TROUBLESHOOTING (TM-39) FAILURE CODE [D5ZCKZ]
20-518 1 HM400-1L
TROUBLESHOOTING (TM-40) FAILURE CODE [DF10KA]
(TM-40) FAILURE CODE [DF10KA]
FORCED NEUTRAL DEMAND SIGNAL (L4)

• Possibly failure in neutral command signal.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DF10KA] Specifications No. Readings
• Disconnect (BRC1, BRC2) connector from retarder controller and install T-adapter on (BRC1, BRC2) wiring harness connector only.
• Disconnect (ATC1, ATC2, ATC5A) connector from transmission controller and install T-adapter on (ATC1, ATC2, ATC5A) wiring harness
connector only
• ✸ Turn ignition switch to the “ON” position for this test
✸ Between ATC5A, (7) and chassis ground. less than 1V 1
✸ Between ATC5A, (8) and chassis ground. less than 1V 2
20 to 30V 4
ground.and chassis ground.
Voltage ✸ Between connector ATC2, (1), (12) and chassis

20 to 30V 5
ground.
✸ Between connector BRC1, (7) and chassis ground. 20 to 30V 6
A. Open or high ✸ Between connector BRC2, (9), (17) and chassis

20 to 30V 7
resistance ground.
20 to 30V 8
ground.
Between connectors BRC1, (6) and ATC5A, (7) 0.0 to 1.0Ω 9
Between connectors BRC1, (15) and ATC5A, (8) 0.0 to 1.0Ω 10
Between connectors ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 11
Resistance Ω
Between connectors ATC2, (21) and chassis ground. 0.0 to 1.0Ω 12
Between connectors BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 13
Between connectors BRC2, (21) and chassis ground. 0.0 to 1.0Ω 14
Between connector BRC1, (6) and chassis ground. (OL) open 15
B. Short to
chassis ground Resistance Ω Between connector BRC1, (15) and chassis ground. (OL) open 16
or within harness
Between connector BRC1, (6) and (15) (OL) open 17
Remark
HM400-1L 20-519 1
20-520 1 HM400-1L
TROUBLESHOOTING (TM-41) FAILURE CODE [D5ZEKX]
(TM-41) FAILURE CODE [D5ZEKX]
ENGINE LOAD SIGNIAL OUT OF RANGE (KX)

• Possibly engine load command signal out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [D5ZEKX] Specifications No. Readings
• Disconnect (CN2, CN4) connector from engine controller and install T-adapter on (CN2, CN4) wiring harness connector only.
• Disconnect (ATC1, ATC2, ATC3A) connector from transmission controller and install T-adapter on (ATC1, ATC2, ATC3A) wiring harness
connector only
• ✸ Turn ignition switch to the “ON” position for this test
Between connector CN4, (9), (18), (20) and chassis
20 to 30V 1
ground, ignition key in the ON position.
Between connector ATC1, (7) and chassis ground. 20 to 30V 2
Voltage Between connector ATC1, (9), (17) and chassis ground,
20 to 30V 3
A. Open or high Between connector ATC2, (1), (12) and chassis ground,
resistance 20 to 30V 4
Between connectors CN2, (14) and ATC3A, (4) 0.0 to 1.0Ω 5
Between connectors CN4, (8), (19) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
Between connectors ATC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 7
B. Short to
chassis ground Resistance Ω Between connector CN2, (14) and chassis ground. (OL) open 9
or within harness
Remark
HM400-1L 20-521 1
TROUBLESHOOTING (TM-41) FAILURE CODE [D5ZEKX]
20-522 1 HM400-1L
TROUBLESHOOTING (TM-42) FAILURE CODE [DAQ0KK]
(TM-42) FAILURE CODE [DAQ0KK]
TRANSMISSION CONTROLLER DROP IN POWER SOURCE (KK)

• Drop in transmission controller power source.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DAQ0KK] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT2-22 and BT3-14) condition Fuses OK? 1 Yes or No
Circuit Breaker Breaker and
⎯ Check (circuit breaker) and fuse link (FU) 2 Yes or No
And Fuse Link Fuse Link OK?
• Disconnect (ATC1) connector from transmission controller and install T-adapter on (ATC1) wiring harness connector only.
Voltage ✸ Between connector ATC1, (17) and chassis ground. 20 to 30V 4
A. Open or high
resistance
Resistance Ω
Between connectors ATC1, (9) and chassis ground. (OL) open 8
B. Short to
or within harness Between connectors ATC1, (7) and chassis ground
(OL) open 10
battery disconnected.
Remark
HM400-1L 20-523 1
20-524 1 HM400-1L

• Transmission controller drop in power source.
Contents Of Trouble

A. Open or high
resistance
Resistance Ω
B. Short to
(OL) open 10
Remark
HM400-1L 20-525 1
20-526 1 HM400-1L
POSSIBLE SHORT OR OPEN IN TRANSMISSION VOLTAGE SYSTEM (KK)

• Short in transmission cut-off relay circuit
Contents Of Trouble

1. Relay Check
• Disconnect (R15) relay and install a known good relay.
Did code [DAQ2KK] disappear and is system working
A. Relay test ⎯ ⎯ 2 Yes or No
normal?
• Disconnect (ATC1 and ATC2) connector from transmission controller and install T-adapter on (ATC1 and ATC2) wiring harness connector only
Voltage
A. Open or high ✸ Between connector ATC1, (9) and chassis ground. 20 to 30V 6
resistance Between connectors R15, (1) and ATC1, (15) 0.0 to 1.0Ω 7
Between connectors R15, (5) and ATC2, (12) 0.0 to 1.0Ω 8
Resistance Ω
B. Short to Between connector ATC2, (12) and chassis ground. (OL) open 11
or within harness Between connector ATC1, (15) and chassis ground. (OL) open 12

Remark
HM400-1L 20-527 1
20-528 1 HM400-1L

• Transmission controller drop in power source.
Contents Of Trouble

A. Open or high
resistance
Resistance Ω
B. Short to
(OL) open 10
Remark
HM400-1L 20-529 1
20-530 1 HM400-1L
TROUBLESHOOTING (TM-46) FAILURE CODE [DAQ5KP]
(TM-46) FAILURE CODE [DAQ5KP]
TRANSMISSION CONTROLLER SIGNAL OUT OF RANGE (KP)

• Transmission power signal possibly out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DAQ5KP] Specifications No. Readings
Was dump operations carried out on slope of more than
Inclination Of Machine ⎯ 15o max. 1 Yes or No
15o
1. Inclination Sensor
• Disconnect (T10) connector from inoculation sensor and isolate sensor.
A. Switch test Resistance Ω At sensor T10, between (2) and (3) 3
• Disconnect (T10) connector from sensor and isolate connector.
• Disconnect (ATC2, ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC2, ATC3A and ATC3B) wiring
harness connector only
Voltage 12V 5
ground.
At controller ATC3A, between (16) and chassis
0.0 to 1.0Ω 6
A. Open or high ground.
resistance
Resistance Ω Between connections T10, (1) and ATC2, (14) 0.0 to 1.0Ω 7
Between connections T10, (2) and ATC3A, (16) 0.0 to 1.0Ω 8
Between connections T10, (3) and ATC3B, (16) 0.0 to 1.0Ω 9
Remark
HM400-1L 20-531 1
TROUBLESHOOTING (TM-46) FAILURE CODE [DAQ5KP]
20-532 1 HM400-1L
TROUBLESHOOTING (TM-47) FAILURE CODE [DAQ9KM]
(TM-47) FAILURE CODE [DAQ9KM]
MISTAKEN OPERATION SETTING (KP)

• Possible mistaken operation in system.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DAQ9KM] Specifications No. Readings
A. Open or high
Resistance Ω Between connector ATC5A, (1) and chassis ground. 0.0 to 1.0Ω 1
resistance
Remark
HM400-1L 20-533 1
TROUBLESHOOTING (TM-48) FAILURE CODE [DAQ9KM]
(TM-48) FAILURE CODE [DAQ9KM]
NO MATCH IN MODEL SELECTION SIGNAL (KP)

• Model selection signal not matching system.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DAQ9KM] Specifications No. Readings
• Disconnect (ATC1 and ATC5B) connector from transmission controller and install T-adapter on (ATC1 and ATC5B) wiring harness connector
only
A. Open or high
Resistance Ω Between connector ATC5B, (14) and chassis ground. 0.0 to 1.0Ω 3
resistance
Between connector ATC5B, (15) and chassis ground. 0.0 to 1.0Ω 4
Between connector ATC5B, (16) and chassis ground. 0.0 to 1.0Ω 5
Remark
20-534 1 HM400-1L
TROUBLESHOOTING (TM-49) FAILURE CODE [DAQAKQ]
12
(TM-49) FAILURE CODE [DAQAKQ]
TRANSMISSION CONTROLLER ROTARY SWITCH

★ Rotary switch does mot match settings
Turn ignition switch to In setting of transmission Set again

NO
the “OFF” position. controller rotary switch correctly? Defective setting of rotary switch
YES
Replace
Defective transmission controller
(TM-50) FAILURE CODE [DAQSMA]
TRANSMISSION FUNCTION INNOPERABLE

★ The command for the (S-NET) with the machine is defective.
Cause Remedy
With ignition switch in Is other failure code [15*8l1] also

the “ON” position. Other problem occurring at the
displayed or recorded at same YES Replace
same time
time?
NO
Does condition become normal Replace

when transmission controller is NO Defective hydraulic mechanical
replaced? system
YES
Replace
Defective transmission controller
HM400-1L 20-535 1
TROUBLESHOOTING (TM-51) FAILURE CODE [DDTFKA]
(TM-51) FAILURE CODE [DDTFKA]
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)

• Lock-up clutch not open or short.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTFKA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
20-536 1 HM400-1L
HM400-1L 20-537 1
(TM-52) FAILURE CODE [DDTFKA]
“LOCK-UP” CLUTCH FILL SWITCH SYSTEM OPEN OR SHORTED (KA)

• Lock-up clutch not open or short.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTFKA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
20-538 1 HM400-1L
HM400-1L 20-539 1
TROUBLESHOOTING (TM-53) FAILURE CODE [DDTHKA]
(TM-53) FAILURE CODE [DDTHKA]
“HI” CLUTCH SYSTEM OPEN OR SHORTED (KA)

• Hi clutch possible open or short in the system.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTHKA] Specifications No. Readings
1. HI Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-540 1 HM400-1L
TROUBLESHOOTING (TM-53) FAILURE CODE [DDTHKA]
HM400-1L 20-541 1
TROUBLESHOOTING (TM-54) FAILURE CODE [DDTJKA]
(TM-54) FAILURE CODE [DDTJKA]
“LO” CLUTCH SYSTEM OPEN OR SHORTED (KA)

• Low clutch possibly open or shorted.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTJKA] Specifications No. Readings
1. Lo Clutch ECMV Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-542 1 HM400-1L
TROUBLESHOOTING (TM-54) FAILURE CODE [DDTJKA]
HM400-1L 20-543 1
TROUBLESHOOTING (TM-55) FAILURE CODE [DDTKKA]
(TM-55) FAILURE CODE [DDTKKA]
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA)

• 1st clutch possibly open or shorted.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTKKA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-544 1 HM400-1L
TROUBLESHOOTING (TM-55) FAILURE CODE [DDTKKA]
HM400-1L 20-545 1
TROUBLESHOOTING (TM-56) FAILURE CODE [DDTLKA]
(TM-56) FAILURE CODE [DDTLKA]
2ND CLUTCH SYSTEM OPEN OR SHORTED (KA)

• 2nd clutch system possibly open or shorted
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTLKA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-546 1 HM400-1L
TROUBLESHOOTING (TM-56) FAILURE CODE [DDTLKA]
HM400-1L 20-547 1
TROUBLESHOOTING (TM-57) FAILURE CODE [DDTMKA]
(TM-57) FAILURE CODE [DDTMKA]
3RD CLUTCH SYSTEM OPEN OR SHORTED (KA)

• 3rd clutch possibly open or shorted.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTMKA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-548 1 HM400-1L
TROUBLESHOOTING (TM-57) FAILURE CODE [DDTMKA]
HM400-1L 20-549 1
TROUBLESHOOTING (TM-58) FAILURE CODE [DDTNKA]
(TM-58) FAILURE CODE [DDTNKA]
“R” CLUTCH SYSTEM OPEN OR SHORTED (KA)

• Reverse clutch possibly open or shorted.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DDTNKA] Specifications No. Readings
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-550 1 HM400-1L
TROUBLESHOOTING (TM-58) FAILURE CODE [DDTNKA]
HM400-1L 20-551 1
12
(TM-59) FAILURE CODE [DF10KA]
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)

• Possible open in gear shift lever system.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Error Code [DF10KA] Specifications No. Readings
Fuse Check ⎯ Check fuses (BT3-10) condition Fuses OK? 1 Yes or No
1. Gear Shift Lever
• Disconnect (SF1) connector from gear shift lever and install T-adapter between (SF1) connector and controller.
At connector SF1, between (1) and (2) 20 to 30V 2
A. Voltage supply test Voltage
Between connector SF1, (1) and chassis ground. 20 to 30V 3
• Disconnect (SF1) connector from shift lever and isolate connector.
• Disconnect (ATC5B and ATC3A) connector from transmission controller and install T-adapter on (ATC5B and ATC3A) wiring harness
connector only.
A. Open or high Voltage ✸ See (Table 1) below illustration 20 to 30V 4 ⎯

resistance Resistance Ω See (Table 2) below illustration 0.0 to 1.0Ω 5 ⎯
B. Short to chassis
ground or within Resistance Ω See (Table 3) below illustration (OL) open 6 ⎯
harness
Remark
20-552 1 HM400-1L
Wiring Harness Assembly Test
★ Table 1 ★ Table 2 ★ Table 3

Between controllers Shift Between connectors Ω Between connectors Ω
Voltage
ATC5B, ATC3A position ATC5B and SF1 value ATC5B and ground value
ATC5B (2) - ATC3A (14) R1 ATC5B (2) - SF1 (4) (2) and ground
ATC5B (4) - ATC3A (14) N ATC5B (4) - SF1 (5) (4) and ground
20 to 30 V
ATC5B (5) - ATC3A (14) D ATC5B (5) - SF1 (6) (5) and ground
0.0 to 1.0Ω
(OL) open
ATC5B (6) - ATC3A (14) 1 ATC5B (6) - SF1 (11) (6) and ground
HM400-1L 20-553 1
TROUBLESHOOTING (TM-60) FAILURE CODE [DF10KB]
(TM-60) FAILURE CODE [DF10KB]
POSSIBLE OPEN OR SHORT IN GEAR SHIFT LEVER SYSTEM (KA)

• Possible open in gear shift lever system.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Error Code [DF10KA] Specifications No. Readings
1. Gear Shift Lever
• Disconnect (SF1) connector from gear shift lever and install T-adapter between (SF1) connector and controller.
At connector SF1, between (1) and (2) 20 to 30V 2
A. Voltage supply test Voltage
Between connector SF1, (1) and chassis ground. 20 to 30V 3
• Disconnect (SF1) connector from shift lever and isolate connector.
• Disconnect (ATC5B and ATC3A) connector from transmission controller and install T-adapter on (ATC5B and ATC3A) wiring harness
connector only.
A. Open or high Voltage ✸ See (Table 1) below illustration 20 to 30V 4 ⎯

resistance Resistance Ω See (Table 2) below illustration 0.0 to 1.0Ω 5 ⎯
B. Short to chassis
ground or within Resistance Ω See (Table 3) below illustration (OL) open 6 ⎯
harness
Remark
20-554 1 HM400-1L
TROUBLESHOOTING (TM-60) FAILURE CODE [DF10KB]
Wiring Harness Assembly Test
★ Table 1 ★ Table 2 ★ Table 3

Between controllers Shift Between connectors Ω Between connectors Ω
Voltage
ATC5B, ATC3A position ATC5B and SF1 value ATC5B and ground value
ATC5B (4) - ATC3A (14) N ATC5B (4) - SF1 (5) (4) and ground
20 to 30 V
ATC5B (5) - ATC3A (14) D ATC5B (5) - SF1 (6) (5) and ground
0.0 to 1.0Ω
(OL) open
HM400-1L 20-555 1
TROUBLESHOOTING (TM-61) FAILURE CODE [DGF1KX]
12
(TM-61) FAILURE CODE [DGF1KX]
TRANSMISSION OIL TEMPERATURE SENSOR OUT OF RANGE (KX)

• Transmission oil temperature sensor system out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DGF1KX] Specifications No. Readings
1. Temperature Sensor
• Disconnect (LUB-T) connector from sensor and isolate temperature sensor unit.
At sensor LUB-T, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
At sensor LUB-T, between (1) and (2) temperature of oil
3.5 to 4.0kΩ 2
around 100oC (212oF)
• Disconnect (LUB-T) connector from sensor.
• Disconnect (ATC3A and ATC3B) connector from transmission controller and install T-adapter on (ATC3A and ATC3B) wiring harness
connector only
Between connector LUB-T, (1) and chassis ground. (OL) open 3
A. Short to
chassis ground Resistance Ω Between connector LUB-T, (2) and chassis ground. (OL) open 4
or within harness
At connector LUB-T, between (1) and (2) (OL) open 5
B. Open or high Between connectors LUB-T, (1) and ATC3B, (9) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors LUB-T, (2) and ATC3A, (16) 0.0 to 1.0Ω 7
Remark
20-556 1 HM400-1L
TROUBLESHOOTING (TM-62) FAILURE CODE [DGR2L8]
12
(TM-62) FAILURE CODE [DGR2L8]
REAR BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)

• Rear brake oil temperature sensor system out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DGR2L8] Specifications No. Readings
• Disconnect (T13) connector from sensor and isolate temperature sensor unit.
At sensor T13, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
3.5 to 4.0kΩ 2
• Disconnect (T13) connector from sensor.
connector only
Between connector T13, (1) and chassis ground. (OL) open 3
A. Short to
or within harness
B. Open or high Between connectors T13, (1) and ATC3B, (10) 0.0 to 1.0Ω 6
Resistance Ω
Remark
HM400-1L 20-557 1
20-558 1 HM400-1L
12
CENTER BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)

• Center brake oil temperature sensor system out of range.
Contents Of Trouble

37 to 50kΩ 1
around 25oC (77oF)
3.5 to 4.0kΩ 2
connector only
A. Short to
or within harness
Resistance Ω
Remark
HM400-1L 20-559 1
20-560 1 HM400-1L
FRONT BRAKE OIL TEMPERATURE SENSOR OUT OF RANGE (L8)

• Front brake oil temperature sensor system out of range.
Contents Of Trouble

37 to 50kΩ 1
around 25oC (77oF)
3.5 to 4.0kΩ 2
connector only
A. Short to
or within harness
Resistance Ω
Remark
HM400-1L 20-561 1
20-562 1 HM400-1L
TROUBLESHOOTING (TM-65) FAILURE CODE [DGT1LX]
12
(TM-65) FAILURE CODE [DGT1LX]
TORQUE CONVERTER TEMPERATURE SENSOR OUT OF RANGE (KX)

• Torque converter temperature sensor system out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DGT1LX] Specifications No. Readings
At sensor TC-SE, between (1) and (2) temperature of oil
37 to 50kΩ 1
around 25oC (77oF)
At sensor TC-SE, between (1) and (2) temperature of oil
3.5 to 4.0kΩ 2
• Disconnect (TC-SE) connector from sensor.
connector only
Between connector TC-SE, (1) and chassis ground. (OL) open 3
A. Short to
chassis ground Resistance Ω Between connector TC-SE, (2) and chassis ground. (OL) open 4
or within harness
At connector TC-SE, between (1) and (2) (OL) open 5
B. Open or high Between connectors TC-SE, (1) and ATC3B, (7) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors TC-SE, (2) and ATC3A, (16) 0.0 to 1.0Ω 7
Remark
HM400-1L 20-563 1
TROUBLESHOOTING (TM-66) FAILURE CODE [DHT5KX]
(TM-66) FAILURE CODE [DHT5KX]
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (KX)

• Torque converter pressure signal possibly out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DHT5KX] Specifications No. Readings
1. Oil Pressure Sensor
• Disconnect (TC-INT) connector from pressure sensor and isolate sensor.
At sensor TC-INT, between (1) and (2) 1
A. Switch test Resistance Ω At sensor TC-INT, between (2) and (3) 2
• Disconnect (TC-INT) connector from sensor and isolate connector.
• Disconnect (ATC3A and ATC1) connector from transmission controller and install T-adapter on (ATC3A and ATC1) wiring harness connector
only
Voltage 24V 4
ground.
Between connections TC-INT, (1) and ATC3A, (17) 0.0 to 1.0Ω 5
A. Open or high
resistance Between connections TC-INT, (1) and ATC3A, (16) 0.0 to 1.0Ω 6
Resistance Ω
Between connections TC-INT, (2) and ATC1, (3) 0.0 to 1.0Ω 7
At connector TC-INT, between (1) and chassis ground. (OL) open 9
B. Short to At connector TC-INT, between (3) and chassis ground. (OL) open 11
or within harness At connector TC-INT, between (1) and (2) (OL) open 12
At connector TC-INT, between (1) and (3) (OL) open 13
Remark
20-564 1 HM400-1L
TROUBLESHOOTING (TM-66) FAILURE CODE [DHT5KX]
HM400-1L 20-565 1
TROUBLESHOOTING (TM-67) FAILURE CODE [DHT5L6]
(TM-67) FAILURE CODE [DHT5L6]
TORQUE CONVERTER OIL PRESSURE SENSOR OUT OF RANGE (L6)

• Torque converter pressure signal possibly out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DHT5L6] Specifications No. Readings
1. Oil Pressure Sensor
• Disconnect (TC-INT) connector from pressure sensor and isolate sensor.
A. Switch test Resistance Ω At sensor TC-INT, between (2) and (3) 2
• Disconnect (TC-INT) connector from sensor and isolate connector.
• Disconnect (ATC3A and ATC1) connector from transmission controller and install T-adapter on (ATC3A and ATC1) wiring harness connector
only
Voltage 24V 4
ground.
A. Open or high
resistance Between connections TC-INT, (1) and ATC3A, (16) 0.0 to 1.0Ω 6
Resistance Ω
Between connections TC-INT, (2) and ATC1, (3) 0.0 to 1.0Ω 7
B. Short to At connector TC-INT, between (3) and chassis ground. (OL) open 11
or within harness At connector TC-INT, between (1) and (2) (OL) open 12
Remark
20-566 1 HM400-1L
TROUBLESHOOTING (TM-67) FAILURE CODE [DHT5L6]
HM400-1L 20-567 1
TROUBLESHOOTING (TM-68) FAILURE CODE [DJF1KA]
(TM-68) FAILURE CODE [DJF1KA]
FUEL LEVEL SENSOR OUT OF RANGE (L6)

• Fuel level sensor not reading correctly.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DJF1KA] Specifications No. Readings
1. Fuel Level Sensor
• Disconnect (T08) connector from sensor and isolate sensor.
At sensor T08, between (1) and (2) tank full. 1
A. Sensor test Resistance Ω At sensor T08, between (1) and (2) tank half full. 2
At sensor T08, between (1) and (2) tank empty. 3
• Disconnect (T08) connector from fuel level sensor.
connector only
A. Open or high Between connectors T08, (1) and ATC3B, (4) 0.0 to 1.0Ω 4
Resistance Ω
B. Short to Between connector T08, (1) and chassis ground. (OL) open 6
Remark
20-568 1 HM400-1L
TROUBLESHOOTING (TM-68) FAILURE CODE [DJF1KA]
HM400-1L 20-569 1
TROUBLESHOOTING (TM-69) FAILURE CODE [DK11KX]
12
(TM-69) FAILURE CODE [DK11KX]
THROTTLE ANGLE SENDOR OUT OF RANGE (KX)

• Throttle angle sensor out of range.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DK11KX] Specifications No. Readings
1. Throttle Angle Sensor
• Disconnect (AS2) connector from angle sensor.
At sensor AS2, between (1) and (3) 1
Ohms
At sensor AS2, between (2) and (1) slowly depressing increases or
2 Yes or No
pedal (from idle position to full throttle position) decrease
A. Sensor test Resistance Ω steadily?
Ohms
At sensor AS2, between (2) and (3) slowly depressing increases or
3 Yes or No
pedal (from idle position to full throttle position) decrease
steadily?
• Disconnect (F.PS) connector from solenoid.
• Disconnect (L63) connector from transmission controller and install T-adapter on (L63) wiring harness connector only
Between connector AS2, (1) and chassis ground. (OL) open 4
Between connector AS2, (2) and chassis ground. (OL) open 5
A. Short to Between connector AS2, (3) and chassis ground. (OL) open 6
or within harness At connector AS2, between (1) and (2) (OL) open 7
At connector AS2, between (1) and (3) (OL) open 8
At connector AS2, between (3) and (2) (OL) open 9
Between connectors AS2, (1) and ATC3A, (6) 0.0 to 1.0Ω 10
B. Open or high
Resistance Ω Between connectors AS2, (2) and ATC3B, (11) 0.0 to 1.0Ω 11
resistance
Between connectors AS2, (3) and ATC3A, (16) 0.0 to 1.0Ω 12
Remark
20-570 1 HM400-1L
TROUBLESHOOTING (TM-69) FAILURE CODE [DK11KX]
HM400-1L 20-571 1
TROUBLESHOOTING (TM-70) FAILURE CODE [DLE2KA]
(TM-70) FAILURE CODE [DLE2KA]
ENGINE SPEED SENSOR OPEN OR SHORTED (KA)

• Open in engine speed sensor.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DLE2KA] Specifications No. Readings
1. Engine Speed Sensor
• Disconnect (EREV) connector from sensor and isolate sensor.
At sensor EREV, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor EREV, between (1) or (2)
(OL) open 2
and chassis ground.
• Disconnect (EREV) connector from sensor.
A. Open or high Between connectors EREV, (1) and ATC3A, (13) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors EREV, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
Between connector EREV, (1) and chassis ground. (OL) open 5
B. Short to
chassis ground Resistance Ω Between connector EREV, (2) and chassis ground. (OL) open 6
or within harness
At connector EREV, between (1) and (2) (OL) open 7
Remark
20-572 1 HM400-1L
TROUBLESHOOTING (TM-71) FAILURE CODE [DLE2LC]
(TM-71) FAILURE CODE [DLE2LC]
ENGINE SPEED SENSOR OPEN OR SHORTED (LC)

• Short in engine speed sensor.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DLE2LC] Specifications No. Readings
1. Engine Speed Sensor
• Disconnect (EREV) connector from sensor and isolate sensor.
At sensor EREV, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor EREV, between (1) or (2)
(OL) open 2
and chassis ground.
• Disconnect (EREV) connector from sensor.
A. Open or high Between connectors EREV, (1) and ATC3A, (13) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors EREV, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
Between connector EREV, (1) and chassis ground. (OL) open 5
B. Short to
chassis ground Resistance Ω Between connector EREV, (2) and chassis ground. (OL) open 6
or within harness
At connector EREV, between (1) and (2) (OL) open 7
Remark
HM400-1L 20-573 1
TROUBLESHOOTING (TM-72) FAILURE CODE [DLF1KA]
(TM-72) FAILURE CODE [DLF1KA]
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (KA)

• Open in transmission speed sensor.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DLF1KA] Specifications No. Readings
1. Transmission Speed Sensor
• Disconnect (N1) connector from sensor and isolate sensor.
At sensor N1, between (1) and (2) 500 to 1000Ω 1
A. Solenoid test Resistance Ω At sensor N1, between (1) or (2)
(OL) open 2
and chassis ground.
• Disconnect (N1) connector from sensor.
A. Open or high Between connectors N1, (1) and ATC3A, (2) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors N1, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
Between connector N1, (1) and chassis ground. (OL) open 5
B. Short to
chassis ground Resistance Ω Between connector N1, (2) and chassis ground. (OL) open 6
or within harness
At connector N1, between (1) and (2) (OL) open 7
Remark
20-574 1 HM400-1L
TROUBLESHOOTING (TM-73) FAILURE CODE [DLF1LC]
(TM-73) FAILURE CODE [DLF1LC]
TRANSMISSION INPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)

• Short in transmission speed sensor.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DLF1LC] Specifications No. Readings
(OL) open 2
and chassis ground.
Resistance Ω
B. Short to
or within harness
Remark
HM400-1L 20-575 1
TROUBLESHOOTING (TM-74) FAILURE CODE [DLF2KA]
(TM-74) FAILURE CODE [DLF2KA]
TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR

SHORTED (KA)
Contents Of Trouble

(OL) open 2
and chassis ground.
Resistance Ω
B. Short to Between connector N2, (1) and chassis ground. (OL) open 5
or within harness At connector N2, between (1) and (2) (OL) open 7
Remark
20-576 1 HM400-1L
TROUBLESHOOTING (TM-75) FAILURE CODE [DLF2LC]
(TM-75) FAILURE CODE [DLF2LC]
TRANSMISSION INTERMEDATE SHAFT SPEED SENSOR OPEN OR

SHORTED (LC)
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DLF2LC] Specifications No. Readings
(OL) open 2
and chassis ground.
Resistance Ω
Remark
HM400-1L 20-577 1
TROUBLESHOOTING (TM-76) FAILURE CODE [DLT3KA]
(TM-76) FAILURE CODE [DLT3KA]
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED

(KA)
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DLT3KA] Specifications No. Readings
(OL) open 2
and chassis ground.
• Disconnect (ATC3A and BRC3A) connector from transmission controller and install T-adapter on (ATC3A and BRC3A) wiring harness
connector only
Between connectors N3, (1) and ATC3A, (3) 0.0 to 1.0Ω 3
A. Open or high
Resistance Ω Between connectors N3, (1) and BRC3A, (13) 0.0 to 1.0Ω 4
resistance
Remark
20-578 1 HM400-1L
TROUBLESHOOTING (TM-76) FAILURE CODE [DLT3KA]
HM400-1L 20-579 1
TROUBLESHOOTING (TM-77) FAILURE CODE [DLT3LC]
(TM-77) FAILURE CODE [DLT3LC]
TRANSMISSION OUTPUT SHAFT SPEED SENSOR OPEN OR SHORTED (LC)

Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DLT3LC] Specifications No. Readings
(OL) open 2
and chassis ground.
• Disconnect (ATC3A and BRC3A) connector from transmission controller and install T-adapter on (ATC3A and BRC3A) wiring harness
connector only
A. Open or high
Resistance Ω Between connectors N3, (1) and BRC3A, (13) 0.0 to 1.0Ω 4
resistance
B. Short to
or within harness
Remark
20-580 1 HM400-1L
TROUBLESHOOTING (TM-77) FAILURE CODE [DLT3LC]
HM400-1L 20-581 1
TROUBLESHOOTING (TM-78) FAILURE CODE [DXH0KA]
(TM-78) FAILURE CODE [DXH0KA]
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KA)

• Differential lock system open or short.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DXH0KA] Specifications No. Readings
1. Differential Lock Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
20-582 1 HM400-1L
HM400-1L 20-583 1
TROUBLESHOOTING (TM-79) FAILURE CODE [DXH0KB]
(TM-79) FAILURE CODE [DXH0KB]
INNER AXLE DIFFERENTIAL LOCK SYSTEM OPEN OR SHORTED (KB)

• Differential lock system open or short.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [DXH0KB] Specifications No. Readings
1. Differential Lock Solenoid And Switch
• Disconnect (D/L-SW) cincture from switch and isolate switch.
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
20-584 1 HM400-1L
HM400-1L 20-585 1
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KA)

• Lock-up clutch system open or short.
Contents Of Trouble

1. Lock-up Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
20-586 1 HM400-1L
HM400-1L 20-587 1
LOCK-UP CLUTCH SYSTEM OPEN OR SHORTED (KB)

• Lock-up clutch system open or short.
Contents Of Trouble

1. Lock-up Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
connector only.
A. Open or high
resistance
Remark
20-588 1 HM400-1L
HM400-1L 20-589 1
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KA)

• High clutch system open or short.
Contents Of Trouble

1. High Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-590 1 HM400-1L
HM400-1L 20-591 1
HIGH CLUTCH SYSTEM OPEN OR SHORTED (KB)

• High clutch system open or short.
Contents Of Trouble

1. High Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-592 1 HM400-1L
HM400-1L 20-593 1
LOW CLUTCH SYSTEM OPEN OR SHORTED (KA)

• Low clutch system open or short.
Contents Of Trouble

1. Low Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-594 1 HM400-1L
HM400-1L 20-595 1
LOW CLUTCH SYSTEM OPEN OR SHORTED (KB)

• Low clutch system open or short.
Contents Of Trouble

1. Low Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-596 1 HM400-1L
HM400-1L 20-597 1
1ST CLUTCH SYSTEM OPEN OR SHORTED (KA)

• 1st clutch system open or short.
Contents Of Trouble

1. 1st Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-598 1 HM400-1L
HM400-1L 20-599 1
1ST CLUTCH SYSTEM OPEN OR SHORTED (KB)

• 1st clutch system open or short.
Contents Of Trouble

1. 1st Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-600 1 HM400-1L
HM400-1L 20-601 1
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KA)

• 2nd. clutch system open or short.
Contents Of Trouble

1. 2nd Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-602 1 HM400-1L
HM400-1L 20-603 1
2ND. CLUTCH SYSTEM OPEN OR SHORTED (KB)

• 2nd. clutch system open or short.
Contents Of Trouble

1. 1st. Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-604 1 HM400-1L
HM400-1L 20-605 1
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)

• 3rd. clutch system open or short.
Contents Of Trouble

1. 3rd. Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-606 1 HM400-1L
HM400-1L 20-607 1
3RD. CLUTCH SYSTEM OPEN OR SHORTED (KB)

• 3rd. clutch system open or short.
Contents Of Trouble

1. 3rd. Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-608 1 HM400-1L
HM400-1L 20-609 1
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KA)

• Reverse clutch system open or short.
Contents Of Trouble

1. Reverse Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-610 1 HM400-1L
HM400-1L 20-611 1
REVERSE CLUTCH SYSTEM OPEN OR SHORTED (KB)

• Reverse clutch system open or short.
Contents Of Trouble

1. Reverse Solenoid And Switch
Resistance Ω
test
0.0 to 1.0Ω 3
system operating.
connector only.
A. Open or high
resistance
Remark
20-612 1 HM400-1L
HM400-1L 20-613 1
TROUBLESHOOTING (TM-94) NO FAILURE CODE DISPLAYED
(TM-94) NO FAILURE CODE DISPLAYED
BACK-UP LIGHTS AND ALARM DO NOT OPERATE

• No back-up lights or warning alarm.
Contents Of Trouble

Steps Circuit Diagnostic Procedures For Failure Code [NONE] Specifications No. Readings
1. Defective Diodes Or Relay
• Turn ignition switch to the “OFF” position.
• Disconnect diodes (D05 and D06) and isolate diodes.
At diode D05, between (1) and (2) reversing meter leads Continuity one
2 Yes or No
to check. way only?
A. Diodes Resistance Ω
At diode D06, between (1) and (2) reversing meter leads Continuity one
3 Yes or No
to check. way only?
B. Relay test — Replace R05 relay with known good relay. System OK? 4 Yes or No
2. Wiring Harness Assembly and Relay Test
• Disconnect (BL47 and BL48), (Back-up Buzzer) connectors and remove relay (R05).
• Disconnect (ATC5B) connector and install T-adapter on (ATC5B) connector only.
• ✸ For this test the ignition key must be in the “ON” position with the relay (R05) and diodes (D05 and D06) installed.
✸ With shift lever set in R1 or R2, at connector BL48,
20 to 30V 5
between (1) and (2)
✸ With shift lever set in R1 or R2, at connector BL47,
Voltage 20 to 30V 6
between (1) and (2)
✸ With shift lever set in R1 or R2, at connector of
20 to 30V 7
back-up buzzer, between (1) and (2)
Between connector BL48, (2) and chassis ground. 0.0 to 1.0Ω 8
Between connector BL47, (2) and chassis ground. 0.0 to 1.0Ω 9
A. Open or high Between connector for alarm, (2) and chassis ground. 0.0 to 1.0Ω 10
resistance ✸ Between connector R05, (2), (4) and chassis ground. 20 to 30V 11
Between connectors BL48, (1) and R05, (3) 0.0 to 1.0Ω 12
Resistance Ω Between connectors BL47, (1) and R05, (1) 0.0 to 1.0Ω 13
Between connectors back-up alarm, (1) and R05, (3) 0.0 to 1.0Ω 14
Between connectors SF1, (3) and R05, (5) 0.0 to 1.0Ω 15
Between connectors SF1, (4) and R05, (5) 0.0 to 1.0Ω 16
Between connectors SF1, (3) and ATC5B, (2) 0.0 to 1.0Ω 17
Between connectors SF1, (4) and ATC5B, (1) 0.0 to 1.0Ω 18
20-614 1 HM400-1L
TROUBLESHOOTING (TM-94) NO FAILURE CODE DISPLAYED
12
Between connector BL48, (1) and chassis ground. (OL) open 19
Between connector BL47, (1) and chassis ground. (OL) open 20
B. Short to
chassis ground Resistance Ω Between connector alarm, (1) and chassis ground. (OL) open 21
or within harness
Between connector SF1, (3) and chassis ground. (OL) open 22
Between connector FS1, (4) and chassis ground. (OL) open 23
Remark
Related diagram circuit
HM400-1L 20-615 1
TESTING AND ADJUSTING (TM-94) NO FAILURE CODE DISPLAYED
12
MEMORANDUM
20-616 HM400-1L
TROUBLESHOOTING OF RETARDER
CONTROLLER SYSTEM (BK MODE)

BK CONTROL SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-709
(BK-1) FAILURE CODE [2A62L1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-732
FRONT DIFFERENTIAL CONTROL VALVE (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-732
(BK-2) FAILURE CODE [2A62LH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-734
FRONT DIFFERENTIAL CONTROL VALVE (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-734
(BK-3) FAILURE CODE [2B62L1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-736
REAR DIFFERENTIAL LOCK CONTROL VALVE (L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-736
(BK-4) FAILURE CODE [2B62LH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-738
REAR DIFFERENTIAL LOCK CONTROL VALVE (LH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-738
(BK-5) FAILURE CODE [2C4MNX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-740
BRAKE COOLING FILTER CLOG INDICATED (NX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-740
(BK-6) FAILURE CODE [2D02CA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-742
LEFT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA) . . . . . . . . . . . . . . . . . . . . . . . 20-742
RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA) . . . . . . . . . . . . . . . . . . . . . . 20-743
CENTER RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA) . . . . . . . . . . . . . . 20-744
CENTER LEFT BRAKE WEAR INDICATOR SWITCH WARNING (CA) . . . . . . . . . . . . . . . . . . . . . . 20-745
(BK-10) FAILURE CODE [2D05CA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-746
RIGHT REAR BRAKE WEAR INDICATOR SWITCH WARNING (CA) . . . . . . . . . . . . . . . . . . . . . . . 20-746
(BK-11) FAILURE CODE [2D06CA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-747
LEFT FEAR BRAKE WEAR INDICATOR SWITCH WARNING (CA) . . . . . . . . . . . . . . . . . . . . . . . . . 20-747
(BK-12) FAILURE CODE [2G42ZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-748
ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-748
(BK-13) FAILURE CODE [2G43ZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-749
ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-749
(BK-14) FAILURE CODE [D1C0KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-750
OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-750
(BK-15) FAILURE CODE [D5ZFKZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-752
NEUTRAL SIGNAL OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-752
(BK-16) FAILURE CODE [D5ZGKZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-754
NEUTRAL SIGNAL OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-754
(BK-17) FAILURE CODE [DB10KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-756
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-756
VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-760
(BK-21) FAILURE CODE [DB19KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-764
MISTAKEN OPERATION OF RETARDER CONTROLLER (KM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-764
(BK-22) FAILURE CODE [DB1SKQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-765
HM400-1L 20-701 1
RETARDER CONTROL S-NET LINE MISMATCHED (KQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-765
(BK-23) FAILURE CODE [DHU2KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-766
ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . 20-766
(BK-24) FAILURE CODE [DHU3KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-768
ACCUMULATOR OIL PRESSURE rear SENSOR OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . 20-768
(BK-25) FAILURE CODE [DK51L5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-770
TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB) . . . . . . . . . . . . . . . . . . . . . . . . 20-770
(BK-26) FAILURE CODE [DK52KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-772
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-772
(BK-27) FAILURE CODE [DK53L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-774
DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-774
BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-776
(BK-29) FAILURE CODE [DLF4KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-778
TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA) . . . . . . . . . . . . . . . 20-778
(BK-30) FAILURE CODE [DLT3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-779
TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA) . . . . . . . . . . . . . . . 20-779
(BK-31) FAILURE CODE [DW71KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-781
EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-781
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-782
(BK-33) FAILURE CODE [DW73KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-784
DUMP SELECTOR VALVE OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-784
(BK-34) FAILURE CODE [DX11KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-786
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . 20-786
(BK-35) FAILURE CODE [DX11KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-787
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . 20-787
(BK-36) FAILURE CODE [DX11KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-788
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY) . . . . . . . . . . . . . . . 20-788
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA) . . . . . . . . . . . . . . 20-789
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB) . . . . . . . . . . . . . . 20-790
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-791
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-793
(BK-41) FAILURE CODE [DX13KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-795
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-795
(BK-42) FAILURE CODE [DX14KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-797
REAR DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . . 20-797
(BK-43) FAILURE CODE [DX15KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-798
FRONT DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ) . . . . . . . . . . . . . . . . . . . . . . 20-798
(BK-44) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-800
PARKING BRAKE SYSTEM FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-800
20-702 1 HM400-1L
HM400-1L 20-703 1
20-704 1 HM400-1L
HM400-1L 20-705 1
20-706 1 HM400-1L
HM400-1L 20-707 1
20-708 1 HM400-1L
TROUBLESHOOTING BK CONTROL SYSTEM CIRCUIT DIAGRAM
BK CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-709 1
20-710 1 HM400-1L
12
HM400-1L 20-711 1
20-712 1 HM400-1L
HM400-1L 20-713 1
20-714 1 HM400-1L
12
MEMORANDUM
HM400-1L 20-715 1

Failure
Code
2A62L1 Front differential lock control valve: * Even when output to front differential • Defective front differential lock oil
(BK-1) See Contents (L1) lock solenoid circuit is turned pressure switch
(Machine with differential lock differ- OFF, signal from front differential lock • Short circuit with chassis ground in
ential) oil pressure switch remains ON switch signal circuit wiring harness
• Defective retarder controller (❋)
2A62LH Front differential lock control valve: *When at least 30 seconds have • Defective front differential lock oil
(BK-2) See Contents (LH) passed after starting engine, even if pressure switch
(Machine with differential lock differ- output is sent to front differential lock • Open in switch signal circuit wiring
ential) solenoid circuit when engine is run- harness
ning, signal from front differential lock • Open in switch GND circuit wiring
oil pressure switch remains OFF
harness
2B62L1 Rear differential lock control valve: * Even when output to rear differential • Defective rear differential lock oil
(BK-3) See Contents (L1) lock solenoid circuit is turned OFF, pressure switch
(Machine with differential lock differ- signal from rear differential lock oil • Short circuit with chassis ground in
ential) pressure switch remains ON switch signal circuit wiring harness
2B62LH Rear differential lock control valve: * When at least 30 seconds have • Defective rear differential lock oil
(BK-4) See Contents (LH) passed after starting engine, even if pressure switch
(Machine with differential lock differ- output is sent to rear differential lock • Open in switch signal circuit wiring
ential) solenoid circuit when engine is run- harness
ning, signal from rear differential lock • Open in switch GND circuit wiring
oil pressure switch remains OFF
harness
2C4MNX Brake cooling filter: Clogged (NX) When brake cooling oil temperature • Clogged brake cooling filter (when
(BK-5) went above 50°C when engine was system is working normally)
running, signal circuit of brake cool- • Defective brake cooling filter
ing filter clogging switch became clogging switch
open (shut off from GND) • Open in switch signal circuit wiring
harness
harness
2D01CA Front brake (right): Wear (CA) When gearshift lever was at N posi- • Worn front brake (right) (when
(BK-6) tion, signal circuit of front brake system is working normally)
(right) wear switch became open • Defective front brake (right) wear
switch
ground in sensor power source
ground in sensor signal circuit
wiring harness
❋ Used as the brake controller in E-SPEC.
20-716 1 HM400-1L

Machine Code
• Switch resistance value • Takes no action • No great effect on machine E01
B39 (male) (1) - (2):
• Oil pressure less than 0.39 MPa {4
kg/cm2}: Min. 1 MΩ
• Oil pressure more than 0.59 MPa
{6 kg/cm2}: Max. 1Ω
B39 (male) (1) - (2):
• Oil pressure less than 0.39 MPa.
{4 kg/cm2}: Min. 1 MΩ

B40 (male) (1) - (2):
B39 (male) (1) - (2):
• Switch resistance value • Takes no action • If machine continues to be used as E01

B03 (male) (1) - (2): it is, there is danger that dirt will
• When normal: Max. 1Ω circulate in brake cooling circuit
• Switch resistance value • Takes no action • If the machine is used as it is, there E01
B28 (male) (1) - (2): is danger that the brake will lose
• When normal: Max. 1Ω its effect
• When worn: Min. 1Ω

Code
HM400-1L 20-717 1
2D02CA Front brake (left): Wear (CA) When gearshift lever was at N • Worn front brake (left) (when system is
(BK-7) position, signal circuit of front working normally)
brake (left) wear switch became • Defective front brake (left) wear switch
open
• Open or short circuit with chassis ground
harness
2D03CA Center brake (right): Wear (CA) When gearshift lever was at N • Worn center brake (right) (when system is
(BK-8) position, signal circuit of center working normally)
brake (right) wear switch became • Defective center brake (right) wear switch
open
harness
2D04CA Center brake (left): Wear (CA) When gearshift lever was at N • Worn center brake (left) (when system is
(BK-9) position, signal circuit of center working normally)
brake (left) wear switch became • Defective center brake (left) wear switch
open
in sensor power source
• circuit wiring harness
2D05CA Rear brake (right): Wear (CA) When gearshift lever was at N • Worn rear brake (right) (when system is
(BK-10) position, signal circuit of rear brake working normally)
(right) wear switch became open • Defective rear brake (right) wear switch
2D06CA Rear brake (left): Wear (CA) When gearshift lever was at N • Worn rear brake (left) (when system is
(BK-11) position, signal circuit of rear brake working normally)
(left) wear switch became open • Defective rear brake (left) wear switch
2G42ZG Accumulator (front): Drop in oil With engine running (continuously • Defective hydraulic, mechanical system of
(BK-12) pressure (ZG) for at least 30 seconds), oil pres- front accumulator
sure of less than 6.86 MPa {70 kg/
2
cm } was input for front accumula-
tor oil pres-sure sensor signal
2G43ZG Accumulator (rear): Drop in oil With engine running (continuously • Defective hydraulic, mechanical system of
(BK-13) pressure (ZG) for at least 30 seconds), oil pres- rear accumulator
sure of less than 6.86 MPa {70 kg/
2} was input for rear accumula-
cm
tor oil pressure sensor signal
20-718 1 HM400-1L

• Takes no action • If the machine is used as it is, there E03

is danger that the brake will lose
its effect
• Takes no action • If the machine is used as it is, there E03

is danger that the brake will lose
its effect
HM400-1L 20-719 1
12
Failure
Code
D1C0KZ Brake cut relay: Open or short circuit When output is sent to brake cut • Defective brake cut relay
(BK-14) (KZ) relay circuit, excessive electric cur- • Open or short circuit with chassis
rent flows; when there is output, no ground, or short circuit with power
electric current flows; when output is source in relay signal circuit wiring
OFF, electric current flows harness
harness
D5ZFKZ Neutral signal 1: Open or short circuit When output is sent to neutral signal • Defective transmission controller
(BK-15) (KZ) 1 circuit, excessive electric current • Open or short circuit with chassis
flows; when there is output, no elec- ground in signal 1 circuit wiring
tric current flows harness
D5ZGKZ Neutral signal 2: Open or short circuit When output is sent to neutral signal • Defective transmission controller
(BK-16) (KZ) 2 circuit, excessive electric current • Open or short circuit with chassis
flows; when there is output, no elec- ground in signal 2 circuit wiring
tric current flows harness
DB10KK Retarder controller (q1): Drop in Both main power source voltage cir- • Other problem occurs at same
(BK-17) power source voltage, input (KK) cuit and direct power source voltage time (failure code AB00MA is
circuit went below 17 V displayed)
• Battery tends to lose power
ground in power source circuit
• wiring harness
• Open in GND circuit wiring
harness
DB11KK Retarder controller (q1) main power Voltage difference between main • Open or short circuit with chassis
(BK-18) supply line: Drop in power supply power source voltage circuit and ground in main power source
voltage, input (KK) direct power source voltage went circuit wiring harness
below 5 V (main power source < • Defective retarder controller (❋)
direct power source)
DB12KK Retarder controller (q1) load power When controller power source volt- • Defective brake cut relay
(BK-19) supply line: Drop in power supply age circuit was normal, solenoid • Open or short circuit with chassis
voltage, input (KK) power source voltage circuit went ground in relay power source
below 17 V circuit wiring harness
ground in relay output circuit wiring
harness
DB13KK Retarder controller (q1) battery direct Voltage of direct power source volt- • Open or short circuit with chassis
(BK-20) power supply line: Drop in power age circuit went below 5 V ground in direct power source
supply voltage, input (KK) circuit wiring harness
DB19KM Retarder controller (q1) wiring har- When ignition switch is ON, input • Mistaken connection of connector
(BK-21) ness: Mistaken operation or mistaken connector check signal does not BRC3 (A, B) and connector BRC5
setting (KM) match setting inside controller (A, B) (when system is working
normally)
• Open in signal 2 circuit wiring
harness
20-720 1 HM400-1L

Machine Code
• Relay resistance value • Turns output to brake cut relay • The whole system of the retarder E03
R14 (male) (1) - (2): 100 - 500Ω OFF controller (q1) stops working
(retarder, inter-axle differential lock,
left and right differential lock, dump,
exhaust brake, neutral signal)
• Failure codes (DB12KK, DHU2KX,
DHU3KX) are displayed at same
time
• Turns neutral signal 1 and signal 2 • Even when transmission output E01
OFF shaft F speed goes above 4200
rpm, the transmission does not
shift to N
• Turns neutral signal 1 and signal 2 • Even when transmission output E01
OFF shaft F speed goes above 4200
shift to N
• Main power source voltage • Takes no action (moves as long as • No great effect on machine E03
BRC1 (9)(17) - (8)(16): 20 - 30 V it is possible to actuate)
• Direct power source voltage
BRC1 (7) - (8)(16): 20 - 30 V
•
• Main power source voltage • Takes no action • No great effect on machine E03
BRC1 (9)(17) - (8)(16): 20 - 30 V
• Solenoid power source voltage • Turns all output circuits OFF • The whole system of the retarder E03
BRC2 (1)(12) - BRC1 (8)(16): • Turns 24V power supply of sensor controller (q1) stops working
20 - 30 V OFF (retarder, inter-axle differential lock,
• Failure codes (DHU2KX, DHU3KX)
are displayed at same time
• Direct power source voltage • Takes no action • No great effect on machine E03
BRC1 (7) - (8)(16): 20 - 30 V
• Wiring harness resistance value • Turns all outputs OFF • The whole system of the retarder E03
BRC5A (female) (1) - ground: Max. • Does not record in trouble data controller (q1) stops working
1Ω (retarder, inter-axle differential lock,
time
HM400-1L 20-721 1
12

Code
DB1SKQ Retarder controller (q1) S-NET Communication (S-NET) with • Other problem occurs at same time
(BK-22) line: Model selection signal mis- transmission controller is defec- (failure codes [DAFSKQ] [DAQAKR]
match (KQ) tive and it is impossible to obtain [DAQSKQ] is displayed)
model selection data
• Open in S-NET circuit wiring harness
DHU2KZ Accumulator oil pressure sensor Voltage of signal circuit of front • Defective front accumulator oil pressure
(BK-23) (front): Input signal outside accumulator oil pressure sensor sensor
range (KX) went below 0.5 V or above 4.5 V • Open or short circuit with chassis ground in
sensor power source circuit wiring harness
DHU3KX Accumulator oil pressure sensor Voltage of signal circuit of rear • Defective rear accumulator oil pressure sensor
(BK-24) (rear): Input signal outside range accumulator oil pressure sensor • Open or short circuit with chassis ground in
(KX) went below 0.5 V or above 4.5 V sensor power source circuit wiring harness
DK51L5 Retarder lever potentiometer: * Signal voltage of potentiometer • Defective retarder lever (❋) (potentiometer,
(BK-25) See separate table (BK) of retarder lever circuit went switch)
below 0.3 V or above 4.7 V, or • Open or short circuit with chassis ground, or
potentiometer signal and switch
signal do not match short circuit with power source in
potentiometer power source circuit signal
• Open or short circuit with chassis ground, or
s h or t c i r c u i t w it h p o we r s o u r c e i n
potentiometer signal signal circuit wiring
harness
short circuit with power source in switch 1
• Open or Openshort circuit with chassis
ground, or short circuit with power source
in switch 2 circuit wiring harness
• Open in switch GND circuit wiring harness
DK52KX Dump lever potentiometer 1: Voltage of potentiometer 1 signal • Defective dump lever (potentiometer)
(BK-26) Input signal outside range (KX) circuit or potentiometer 2 signal • Open or short circuit with chassis ground, or
c i r c u i t w e nt b el o w 0 . 3 V o r short circuit with power source in power
above 4.7 V
source circuit wiring harness
• Open in GND circuit wiring harness
short circuit with power source in signal 1
20-722 1 HM400-1L
12

• Only inter-axle differential lock • Inter-axle differential lock system E03
system is not controlled does not work
• Sensor power source voltage • Takes no action • No great effect on machine E01
B25 (2) - (1): 20 - 30 V
B25 (3) - (1): 000 - 000 V
• Sensor power source voltage • Takes no action • No great effect on machine E01
B24 (2) - (1): 20 - 30 V
B24 (3) - (1): 1.8 - 3.5 V
• Potentiometer power source voltage Depending on condition of occur- Depending on nature of action E01
RTL (1) - (3): 4.1 - 4.8 V rence of failure • No great effect on machine
• Potentiometer signal voltage • Carries out control with • Fine control of retarder is
RTL (2) - (3): 0.3 - 4.7 V potentiometer signal impossible (which is not used in E-
• Switch resistance value • Limits output to solenoid to 70% SPEC)
(lever at RELEASED position) • Turns output to solenoid OFF • Retarder does not work (foot brake
• RTL (male) (4) - (6): Max. 1Ω works) (which is not used in E-
• RTL (male) (5) - (6): Min. 1 MΩ SPEC)
• Switch resistance value (lever at
APPLIED position)
• RTL (male) (4) - (6): Min. 1 MΩ
• RTL (male) (5) - (6): Max. 1Ω
• Potentiometer power source Recognizes dump lever position as • Dump body does not move E03
voltage HOLD
HSL (4) - (1): 4.6 - 5.4 V
• Potentiometer signal voltage
HSL (3) - (1) (signal 1): 0.3 - 4.7 V
HSL (2) - (1) (signal 2): 0.3 - 4.7 V
HM400-1L 20-723 1
12

Code
DK53L8 Dump lever potentiometer 2: * Total voltage of potentiometer 1 • Defective dump lever (potentiometer)
(BK-27) See Contents (L8) signal circuit and potentiometer • Open or short circuit with chassis ground, or
2 signal circuit went below 4.4 V short circuit with power source in signal 1
or above 5.6 V
DK54KX Body positioner sensor: Input Voltage of body positioner sen- • Defective body positioner sensor
(BK-28) signal outside range (KX) sor signal circuit went below 0.3 • Open or short circuit with chassis ground, or
V or above 4.7 V short circuit with power source in sensor
power source circuit wiring harness
short circuit with power source in sensor
signal circuit wiring harness
DLF4KA Transmission output shaft F Open has occurred in signal cir- • Defective transmission output shaft F
(BK-29) speed sensor: Open (KA) cuit of transmission output shaft speed sensor or defective adjustment
F speed sensor and signal is not • Open in sensor signal wiring harness
input
DLT3KA Transmission output shaft R Open has occurred in signal cir- • Defective transmission output shaft R
(BK-30) speed sensor: Open (KA) cuit of transmission output shaft speed sensor or defective adjustment
R speed sensor and signal is not • Open in sensor signal wiring harness
input
• Open in sensor GND circuit wiring harness
DW71KZ Exhaust brake solenoid: Open or When output is sent to exhaust • Defective exhaust brake solenoid
(BK-31) short circuit (KZ) brake solenoid circuit, exces- • Open or short circuit with chassis ground, or
(Machine with exhaust brake) sive electric current flows; when short circuit with
there is output, no electric cur-
rent flows; when output is OFF, • power source in solenoid signal circuit
electric current flows wiring harness
• Open in solenoid GND circuit wiring
harness
DW72KZ Dump lever kick-out solenoid: When output is sent to dump • Defective dump lever (kick-out solenoid)
(BK-32) Open or short circuit (KZ) lever kick-out solenoid circuit, • Open or short circuit with chassis ground, or
excessive electric current flows; short circuit with power source in solenoid
when there is output, no electric
current flows; when output is signal circuit wiring harness
OFF, electric current flows • Open in solenoid GND circuit wiring
harness
DW73KZ Dump selector valve solenoid: When output is sent to dump • Defective dump pilot valve (selector
(BK-33) Open or short circuit (KZ) selector valve solenoid circuit, solenoid)
excessive electric current flows; • Open or short circuit with chassis ground, or
when there is output, no electric
current flows; when output is short circuit with power source in solenoid
OFF, electric current flows signal circuit wiring harness
• Open in solenoid GND circuit wiring
harness
20-724 1 HM400-1L

• Potentiometer power source • Recognizes dump lever position • Dump body does not move E03
voltage as HOLD
HSL (4) - (1): 4.6 - 5.4 V
Potentiometer signal voltage
HSL (3) - (1) (signal 1): 0.3 - 4.7 V
HSL (2) - (1) (signal 2): 0.3 - 4.7 V
• Sensor power source voltage • Carries out dump control accord- • here is a big shock when dump E03
B34 (3) - (1): 4.6 - 5.4 V ing to signal from dump lever body is seated
• Sensor signal voltage • Recognizes that dump body is not • Dump lever positioner function
B34 (2) - (1) seated when carrying out control does not work
When seated: 0.30 - 0.46 V • Maximum travel speed range is
When fully raised: 4.00 - 4.70 V limited
• Machine cannot travel in reverse if
dump lever is not at FLOAT
• Sensor resistance value • Cancels inter-axle differential lock • Inter-axle differential lock does not E01
FE1 (male) (1) - (2): 500 - 1000Ω command work
• Does not output neutral signal • Even when transmission output
shaft F speed goes above 4200
shift to N
• Sensor resistance value • Cancels inter-axle differential lock • Inter-axle differential lock does not E01
FE1 (male) (1) - (2): 500 - 1000Ω command work
• Solenoid resistance value Turns output to exhaust brake sole- • Exhaust brake does not work E01
B29 (male) (1) - (2): 20 - 60Ω noid OFF
• Solenoid resistance value • Turns output to dump lever kick- • Dump lever is not locked in detent E01
LKO (male) (1) - (2): 39Ω ± 5% out solenoid OFF
• Solenoid resistance value • Turns output to dump selector • Dump body does not move E03
B31 (male) (1) - (2): Approx. 30Ω valve solenoid OFF
• Turns output to dump EPC valve
solenoid OFF
HM400-1L 20-725 1
12

Code
DX11KA Rear brake pressure reducing valve When output is sent to rear brake • Defective rear brake pressure
(BK-34) solenoid: Open (KA) pressure reducing valve solenoid cir- reducing valve solenoid
cuit, no electric current flows • Open in solenoid (+) circuit wiring
harness
• Open in solenoid (–) circuit wiring
harness
DX11KB Rear brake pressure reducing valve When output is sent to rear brake • Defective rear brake pressure
(BK-35) solenoid: Short circuit (KB) pressure reducing valve solenoid cir- reducing valve solenoid
cuit, excessive electric current flows • Short circuit or short circuit with
chassis ground in solenoid (+)
DX11KY Rear brake pressure reducing valve When output to rear brake pressure • Short circuit with power source in
(BK-36) solenoid: Short circuit in power reducing valve solenoid circuit is solenoid (+) circuit wiring harness
source line (KY) OFF, electric current flows • Short circuit with power source in
solenoid (–) circuit wiring harness
DX12KA Front brake pressure reducing valve When output is sent to front brake • Defective front brake pressure
(BK-37) solenoid: Open (KA) pressure reducing valve solenoid cir- reducing valve solenoid
cuit, no electric current flows • Open in solenoid (+) circuit wiring
harness
harness
DX12KB Front brake pressure reducing valve When output is sent to front brake • Defective front brake pressure
(BK-38) solenoid: Short circuit (KB) pressure reducing valve solenoid cir- reducing valve solenoid
cuit, excessive electric current flows • Short circuit or short circuit with
DX12KY Front brake pressure reducing valve When output to front brake pressure • Short circuit with power source in
(BK-39) solenoid: Short circuit in power reducing valve solenoid circuit is solenoid (+) circuit wiring harness
source line (KY) OFF, electric current flows • Short circuit with power source in
DX13KA Dump EPC valve solenoid: Open When output is sent to dump EPC • Defective dump pilot valve (EPC
(BK-40) (KA) valve solenoid circuit, no electric cur- solenoid)
rent flows • Open in solenoid (+) circuit wiring
harness
harness
20-726 1 HM400-1L

• Solenoid resistance value • Turns output to rear brake • Rear brake (center brake, rear E03
B18 (male) (1) - (2): 10~30Ω pressure reducing valve solenoid brake) does not work
OFF
• Solenoid resistance value • Turns output to rear brake • Rear brake (center brake, rear E03
B18 (male) (1) - (2): 10~30Ω pressure reducing valve solenoid brake) does not work
OFF
• Turns output to rear brake • The whole system of the retarder E03
pressure reducing valve solenoid controller (❋ ) stops working
OFF (retarder, inter-axle differential lock,
• Turns output to brake cut relay left and right differential lock, dump,
OFF exhaust brake, neutral signal)
time
• Solenoid resistance value • Turns output to front brake • Front brake does not work E03
B19 (male) (1) - (2): 10~30Ω pressure reducing valve solenoid
OFF
• Solenoid resistance value • Turns output to front brake • Front brake does not work E03
B19 (male) (1) - (2): 10~30Ω pressure reducing valve solenoid
OFF
• • Turns output to front brake • The whole system of the retarder E03
pressure reducing valve solenoid controller (❋ ) stops working
OFF (retarder, inter-axle differential lock,
• Turns output to brake cut relay left and right differential lock, dump,
OFF exhaust brake, neutral signal)
time
• Solenoid resistance value • Turns output to dump selector • Dump body does not work E03
B32 (male) (1) - (2): Approx. valve solenoid OFF
5~20Ω • Turns output to dump EPC valve
solenoid OFF
HM400-1L 20-727 1
12

Code
DX13KB Dump EPC valve solenoid: Short cir- When output is sent to dump EPC • Defective dump pilot valve (EPC
(BK-41) cuit (KB) valve solenoid circuit, excessive solenoid)
electric current flows • Short circuit or short circuit with
DX13KY Dump EPC valve solenoid: Short cir- When output to dump EPC valve • Short circuit with power source in
(BK-42) cuit in power source line (KY) solenoid circuit is OFF, electric cur- solenoid (+) circuit wiring harness
rent flows • Short circuit with power source in
DX14KZ Rear differential lock solenoid: Open When output is sent to rear differen- • Defective rear differential lock
(BK-43) or short circuit (KZ) tial lock solenoid circuit, excessive solenoid
(Machine with differential lock differ- electric current flows; when there is • Open or short circuit with chassis
ential) output, no electric current flows;
when output is OFF, electric current ground, or short circuit with power
flows source in solenoid signal circuit
wiring harness
• Open in solenoid GND circuit
wiring harness
DX15KZ Front differential lock solenoid: Open When output is sent to front differen- • efective front differential lock
(BK-44) or short circuit (KZ) tial lock solenoid circuit, excessive solenoid
(Machine with differential lock differ- electric current flows; when there is • Open or short circuit with chassis
ential) output, no electric current flows;
when output is OFF, electric current ground, or short circuit with power
flows source in solenoid signal circuit
wiring harness
• Open in coolant in solenoid GND
20-728 1 HM400-1L

• Solenoid resistance value • Turns output to dump selector • Dump body does not work E03
B32 (male) (1) - (2): 15~20Ω valve solenoid OFF
solenoid OFF
• Turns output to dump selector • Dump body does not work E03
valve solenoid OFF
solenoid OFF
• Solenoid resistance value • Turns output to rear differential • Rear differential lock (center E03
B36 (male) (1) - (2): 15~30Ω lock solenoid OFF differential, rear differential) does
not work
• Solenoid resistance value • Turns output to front differential • Front differential lock does not E03
B35 (male) (1) - (2): 15~30Ω lock solenoid OFF work
Failure phenomena of L Series problem codes (L*)
Problem code Nature of problem (phenomenon, nature of problem that occurs)

L6 Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature
HM400-1L 20-729 1

• Failure.

Your
or Voltage
Your
information
2. Diode Test


Your
information
A. Open or high Resistance Ω
Your
information
Your
B. Short to chassis information
Resistance Ω
ground or within
or Voltage Your
harness
information

Resistance Ω Your
20-730 1 HM400-1L

HM400-1L 20-731 1
TROUBLESHOOTING (BK-1) FAILURE CODE [2A62L1]
(BK-1) FAILURE CODE [2A62L1]
FRONT DIFFERENTIAL CONTROL VALVE (L1)

• Even when the output to the front differential lock solenoid circuit is turned OFF, the signal from the front
Contents Of Trouble
differential lock oil pressure switch remains ON.

Steps Circuit Diagnostic Procedures For Failure Code [2A62L1] Specifications No. Readings
1. Hydraulic Mechanical System

• With engine running and the differential lock system set in the OFF mode.
★ If your answer is NO, the problem is in the hydraulic mechanical system. Do not continue with electrical troubleshooting.
Lock system check ⎯ ★Is front differential lock system canceled? ⎯ 1 Yes or No
2. Front Differential Lock Switch

• Disconnect (B39) connector from lock switch and isolate switch.
At switch B39, between (1) and (2) (OL) open 2

At switch B39, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect (BRC5A) connector from the retarder controller and install T-adapter on (BRC5A) wiring harness connector only.
A. Open or high Between connectors B39, (1) and BRC5A, (11) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors B39, (2) and chassis ground. 0.0 to 1.0Ω 5
B. Short to chassis At connector B39, between (1) and chassis ground. (OL) open 6
harness At connector B39, between (1) and (2) (OL) open 7
4. Retarder Controller Unit

Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Controller Unit.
20-732 1 HM400-1L
TROUBLESHOOTING (BK-1) FAILURE CODE [2A62L1]
HM400-1L 20-733 1
TROUBLESHOOTING (BK-2) FAILURE CODE [2A62LH]
(BK-2) FAILURE CODE [2A62LH]
FRONT DIFFERENTIAL CONTROL VALVE (LH)

• When at least 30 seconds have passed after starting the engine, even if output is sent to the front differential lock
Contents Of Trouble solenoid circuit when the engine is running, the signal from the front differential lock oil pressure switch remains
OFF.

Steps Circuit Diagnostic Procedures For Failure Code [2A62LH] Specifications No. Readings

• With engine running and the differential lock system set in the ON mode.
Lock system check ⎯ ★Is front differential lock system actuated? ⎯ 1 Yes or No
2. Front Differential Lock Switch

• Disconnect (B39) connector from lock switch and isolate switch.


Resistance Ω
resistance Between connectors B39, (2) and chassis ground. 0.0 to 1.0Ω 5

Remark
20-734 1 HM400-1L
TROUBLESHOOTING (BK-2) FAILURE CODE [2A62LH]
HM400-1L 20-735 1
TROUBLESHOOTING (BK-3) FAILURE CODE [2B62L1]
(BK-3) FAILURE CODE [2B62L1]
REAR DIFFERENTIAL LOCK CONTROL VALVE (L1)

• Even when the output to the rear differential lock solenoid circuit is turned OFF, the signal from the rear differential
Contents Of Trouble
lock oil pressure switch remains ON

Steps Circuit Diagnostic Procedures For Failure Code [2B62L1] Specifications No. Readings

• With engine running and the differential lock system set in the OFF mode.
Lock system check ⎯ ★Is rear differential lock system canceled? ⎯ 1 Yes or No
2. Rear And Center Differential Switch



• Disconnect (B40 and B41) connectors from switch and isolate connector.
Between connectors B40, (1) and BRC5A, (12) 0.0 to 1.0Ω 6

A. Open or high
Resistance Ω Between connectors B40, (2) and B41, (1) 0.0 to 1.0Ω 7
resistance
Between connectors B41, (2) and chassis ground. 0.0 to 1.0Ω 8
At connector B40, between (1) and chassis ground. (OL) open 9

At connector B41, between (1) and (2) (OL) open 12

Remark
20-736 1 HM400-1L
TROUBLESHOOTING (BK-3) FAILURE CODE [2B62L1]
HM400-1L 20-737 1
TROUBLESHOOTING (BK-4) FAILURE CODE [2B62LH]
(BK-4) FAILURE CODE [2B62LH]
REAR DIFFERENTIAL LOCK CONTROL VALVE (LH)

• When at least 30 seconds have passed after starting the engine, even if output is sent to the rear differential lock
Contents Of Trouble
solenoid circuit when the engine is running, the signal from the rear differential lock oil pressure switch remains OFF

Steps Circuit Diagnostic Procedures For Failure Code [2B62LH] Specifications No. Readings

• With engine running and the differential lock system set in the ON mode.
Lock system check ⎯ ★Is rear differential lock system actuated? ⎯ 1 Yes or No
2. Rear And Center Differential Switch



• Disconnect (B40 and B41) connectors from switch and isolate connector.

A. Open or high
Resistance Ω Between connectors B40, (2) and B41, (1) 0.0 to 1.0Ω 7
resistance
Between connectors B41, (2) and chassis ground. 0.0 to 1.0Ω 8


Remark
20-738 1 HM400-1L
TROUBLESHOOTING (BK-4) FAILURE CODE [2B62LH]
HM400-1L 20-739 1
TROUBLESHOOTING (BK-5) FAILURE CODE [2C4MNX]
(BK-5) FAILURE CODE [2C4MNX]
BRAKE COOLING FILTER CLOG INDICATED (NX)
• When the brake cooling oil temperature went above 50oC (122oF) when the engine was running, the signal circuit of
Contents Of Trouble
the brake cooling filter clogging switch became open (shut off from GND).

Steps Circuit Diagnostic Procedures For Failure Code [2C4MNX] Specifications No. Readings
Brake Cooling Filter ⎯ Check condition of brake filter Filter good? 1 Yes or No
1. Cooling Oil Switch

• Disconnect B05) connector from switch and isolate switch.
At solenoid B03, between (1) and (2) 0.0 to 1.0Ω 2

A. Switch Resistance Ω

• Disconnect (B03) connectors from switch and isolate connector.
Resistance Ω
resistance Between connector B03, (2) and chassis ground. 0.0 to 1.0Ω 5

Remark
20-740 1 HM400-1L
TROUBLESHOOTING (BK-5) FAILURE CODE [2C4MNX]
HM400-1L 20-741 1
TROUBLESHOOTING (BK-6) FAILURE CODE [2D02CA]
(BK-6) FAILURE CODE [2D02CA]
LEFT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)

• When the gearshift lever was at the N position, the signal circuit of the front brake (left) wear switch became open 1.
Contents Of Trouble
Is front brake (left) worn?

Steps Circuit Diagnostic Procedures For Failure Code [2D02CA] Specifications No. Readings
Lining worn
Left Front Brake ⎯ Check condition of left front brake lining 1 Yes or No
out?
1. Left Front Brake Warning Switch

• Disconnect (DT2-2) connector from brake wear switch and isolate switch.
At switch DT2-2, between (1) and (2) (OL) open 2

At switch DT2-2, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect (DT2-2) connectors from switch and isolate connector.
• Disconnect (BRC1 and BRC5B) connector from the retarder controller and install T-adapter on (BRC1 and BRC5B) wiring harness
connector only.
A. Open or high Between connectors DT2-2, (1) and BRC1, (1) 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC5B, (2) 0.0 to 1.0Ω 5
At connector DT2-2, between (1) and chassis ground. (OL) open 6

B. Short to chassis
ground or within Resistance Ω At connector DT2-2, between (2) and chassis ground. (OL) open 7
harness
At connector DT2-2, between (1) and (2) (OL) open 8

Remark
20-742 1 HM400-1L
RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)

• When the gearshift lever was at the N position, the signal circuit of the front brake (right) wear switch became open 1.
Contents Of Trouble
Is front brake (right) worn?

Lining worn
Right Front Brake ⎯ Check condition of right front brake lining 1 Yes or No
out?
1. Right Front Brake Warning Switch



connector only.
Resistance Ω

B. Short to chassis
harness

Remark
HM400-1L 20-743 1
CENTER RIGHT FRONT BRAKE WEAR INDICATOR SWITCH WARNING (CA)

• When the gearshift lever was at the N position, the signal circuit of the center brake (right) wear switch became open
Contents Of Trouble
1. Is center brake (right) worn?

Lining worn
Right Center Brake ⎯ Check condition of right center brake lining 1 Yes or No
out?
1. Right Center Brake Warning Switch



connector only.
Resistance Ω

B. Short to chassis
harness

Remark
20-744 1 HM400-1L
CENTER LEFT BRAKE WEAR INDICATOR SWITCH WARNING (CA)

• When the gearshift lever was at the N position, the signal circuit of the center brake (left) wear switch became open 1.
Contents Of Trouble
Is center brake (left) worn?

Lining worn
Left Center Brake ⎯ Check condition of left center brake lining 1 Yes or No
out?
1. Left Center Brake Warning Switch



connector only.
Resistance Ω

B. Short to chassis
harness

Remark
HM400-1L 20-745 1
RIGHT REAR BRAKE WEAR INDICATOR SWITCH WARNING (CA)

• When the gearshift lever was at the N position, the signal circuit of the rear brake (right) wear switch became open 1.
Contents Of Trouble
Is rear brake (right) worn?

Lining worn
Right Rear Brake ⎯ Check condition of right rear brake lining 1 Yes or No
out?
1. Right Rear Brake Warning Switch



connector only.
Resistance Ω

B. Short to chassis
harness

Remark
20-746 1 HM400-1L
LEFT FEAR BRAKE WEAR INDICATOR SWITCH WARNING (CA)

• When the gearshift lever was at the N position, the signal circuit of the rear brake (left) wear switch became open 1. Is
Contents Of Trouble
rear brake (left) worn?

Lining worn
Left Rear Brake ⎯ Check condition of left rear brake lining 1 Yes or No
out?
1. Left Rear Brake Warning Switch



connector only.
Resistance Ω

B. Short to chassis
harness

Remark
HM400-1L 20-747 1
TROUBLESHOOTING (BK-12) FAILURE CODE [2G42ZG]
(BK-12) FAILURE CODE [2G42ZG]
ACCUMULATOR (FRONT): DROP IN OIL PRESSURE (ZG)

★ Nature of failure: With the engine running (continuously for at least 30 seconds), oil pressure of less than 6.86 MPa {70
kg/cm2} was input for the front accumulator oil pressure sensor signal
Cause Remedy
NO
Defective retarder controller Repair
See TESTING AND Has accumulator oil pressure

ADJUSTING (brake oil pressure) dropped?
Defective hydraulic, mechanical Carry out trouble-

YES system in accumulator oil shooting of the
pressure (brake oil pressure) mechanical system
20-748 1 HM400-1L
TROUBLESHOOTING (BK-13) FAILURE CODE [2G43ZG]
12
(BK-13) FAILURE CODE [2G43ZG]
ACCUMULATOR (REAR): DROP IN OIL PRESSURE (ZG)

★ Nature of failure: With the engine running (continuously for at least 30 seconds), oil pressure of less than 6.86 MPa {70
kg/cm2} was input for the rear accumulator oil pressure sensor signal
Cause Remedy
NO
Defective retarder controller Repair
See TESTING AND Has accumulator oil pressure

ADJUSTING (brake oil pressure) dropped?
Defective hydraulic, mechanical Carry out trouble-

YES system in accumulator oil shooting of the
pressure (brake oil pressure) mechanical system
HM400-1L 20-749 1
TROUBLESHOOTING (BK-14) FAILURE CODE [D1C0KZ]
(BK-14) FAILURE CODE [D1C0KZ]
OPEN OR SHORT IN BRAKE RELAY CIRCUIT (KZ)

• When output is sent to the brake cut relay circuit, excessive electric current flows; when there is output, no electric
Contents Of Trouble
current flows; when the output is OFF, electric current flows.

Steps Circuit Diagnostic Procedures For Failure Code [D1C0KZ] Specifications No. Readings

1. Brake Cut Relay
A. Relay check ⎯ Is failure code [D1C0KZ] gone? ⎯ 2 Yes or No

• Disconnect (BRC1 and BRC2) connector from the retarder controller and install T-adapter on (BRC1 and BRC2) wiring harness connector only.
Between connection BRC1, (17), (9) and chassis

(OL) open 3
A. Short to ground, fuse removed.
Between connection R14, (3) and chassis ground. (OL) open 4
or within harness
At connection R14, (1) and chassis ground. (OL) open 5
✸ Between connection R14, (5) and chassis ground. 20 to 30V 6

Voltage ✸ Between connection BRC1, (9) and chassis ground. 20 to 30V 7
✸ Between connection BRC1, (17) and chassis ground. 20 to 30V 8

B. Open or high
Between connection R14, (3) and BRC2, (1) and (12) 0.0 to 1.0Ω 9
resistance
At connection R14, (2) and chassis ground. 0.0 to 1.0Ω 10
Resistance Ω
At connection BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 11
Between connection R14, (1) and BRC1, (13) 0.0 to 1.0Ω 12

Remark
20-750 1 HM400-1L
TROUBLESHOOTING (BK-14) FAILURE CODE [D1C0KZ]
HM400-1L 20-751 1
TROUBLESHOOTING (BK-15) FAILURE CODE [D5ZFKZ]
(BK-15) FAILURE CODE [D5ZFKZ]
NEUTRAL SIGNAL OPEN OR SHORTED (KZ)

• When output is sent to the neutral signal 1 circuit, excessive electric current flows; when there is output, no electric
Contents Of Trouble
current flow

Steps Circuit Diagnostic Procedures For Error Code [D5ZFKZ] Specifications No. Readings

• Disconnect transmission controller (ATC1, ATC2, ATC5A) and install T-adapter on wiring harness only.
• Disconnect (BRC1, BRC2) connector from retarder controller and install T-adapter on wiring harness connector only.
Between connector BRC1, (6) and ATC5A, (7) 0.0 to 1.0Ω 1

Between connector BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 3
Resistance Ω
✸ Between connector BRC1, (6) and chassis ground. less then 1V 7

A. Open or high ✸ Between connector BRC1, (7) and chassis ground. 20 to 30V 8
resistance

20 to 30V 10
ground.
Voltage
20 to 30V 11
ground.

20 to 30V 12
ground.

20 to 30V 13
ground.
B. Short to At connector BRC1, (6) and chassis ground. (OL) open 14

chassis ground
Resistance Ω At connector BRC1, (15) and chassis ground. (OL) open 15
or within harness
At connector BRC1, between (6) and (15) (OL) open 16
2. Retarder Or Transmission Controller Unit

Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Or Transmission
20-752 1 HM400-1L
TROUBLESHOOTING (BK-15) FAILURE CODE [D5ZFKZ]
HM400-1L 20-753 1
TROUBLESHOOTING (BK-16) FAILURE CODE [D5ZGKZ]
(BK-16) FAILURE CODE [D5ZGKZ]
NEUTRAL SIGNAL OPEN OR SHORTED (KZ)

• When output is sent to the neutral signal 1 circuit, excessive electric current flows; when there is output, no electric
Contents Of Trouble
current flow

Steps Circuit Diagnostic Procedures For Error Code [D5ZGKZ] Specifications No. Readings

• Disconnect transmission controller (ATC1, ATC2, ATC5A) and install T-adapter on wiring harness only.
• Disconnect (BRC1, BRC2) connector from retarder controller and install T-adapter on wiring harness connector only.

Between connector BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 3
Resistance Ω
✸ Between connector BRC1, (15) and chassis ground. less then 1V 7

A. Open or high ✸ Between connector BRC1, (7) and chassis ground. 20 to 30V 8
resistance

20 to 30V 10
ground.
Voltage
20 to 30V 11
ground.

20 to 30V 12
ground.

20 to 30V 13
ground.and chassis ground.
B. Short to At connector BRC1, (6) and chassis ground. (OL) open 14

chassis ground
Resistance Ω At connector BRC1, (15) and chassis ground. (OL) open 15
or within harness
At connector BRC1, between (6) and (15) (OL) open 16
2. Retarder Or Transmission Controller Unit

Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder Or Transmission
20-754 1 HM400-1L
TROUBLESHOOTING (BK-16) FAILURE CODE [D5ZGKZ]
HM400-1L 20-755 1
TROUBLESHOOTING (BK-17) FAILURE CODE [DB10KK]
(BK-17) FAILURE CODE [DB10KK]
DROP IN VOLTAGE FOR RETARDER SYSTEM (KK)

• Nature of failure: Both the main power source voltage circuit and the direct power source voltage circuit went below
17 V
Contents Of Trouble • Before starting troubleshooting, check that the circuit breaker is not OFF, and that the fusible link, fuse BT2-22, and
fuse BT3-12 are normal (if the circuit breaker is OFF or any fuse is blown, there has probably been a surge of current
caused by a short circuit, so check the related circuits).

Steps Circuit Diagnostic Procedures For Failure Code [DB10KK] Specifications No. Readings
Fuses Check ⎯ Check condition of fuses (BT2-22) and (BT3-12) Fuses good? 1 Yes or No
Circuit Breaker ⎯ Check condition of circuit breaker Breaker set? 2 Yes or No
Fuse Link ⎯ Check condition of fuse link (FU) Link good? 3 Yes or No

• Disconnect (BRC1) connector from the retarder controller and install T-adapter on (BRC1) wiring harness connector only.
Resistance Ω Between connectors BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 4
A. Open or high ✸ Between connectors BRC1, (7) and chassis ground 20 to 30V 5
resistance Voltage ✸ Between connectors BRC1, (17) and chassis ground 20 to 30V 6
✸ Between connectors BRC1, (9) and chassis ground 20 to 30V 7
At connector BRC1, between (7) and chassis ground.

(OL) open 8
Fuses removed.
B. Short to chassis
ground or within Resistance Ω (OL) open 9
Fuses removed.
harness
(OL) open 10
Fuses removed.

Remark
20-756 1 HM400-1L
HM400-1L 20-757 1

17 V



(OL) open 8
Fuses removed.
B. Short to chassis
Fuses removed.
harness
(OL) open 10
Fuses removed.

Remark
20-758 1 HM400-1L
HM400-1L 20-759 1
VOLTAGE DROP IN CONTROLLER POWER SUPPLY (KK)

• Nature of failure: The voltage difference between the main power source voltage circuit and the direct power source
voltage went below 5 V (main power source < direct power source)
Contents Of Trouble • Before starting troubleshooting, check that the circuit breaker is not OFF, and that fuse BT3-12 is normal (if the circuit
breaker is OFF or the fuse is blown, there has probably been a surge of current caused by a short circuit, so check the
related circuits).

1. Brake Cut Relay

A. Relay check ⎯ Is failure code [D1C0KZ] gone? ⎯ 2 Yes or No

Between connection BRC1, (17), (9) and chassis

(OL) open 3
A. Short to ground, fuse removed.
or within harness
At connection R14, (1) and chassis ground. (OL) open 5
Voltage ✸ Between connection BRC1, (9) and chassis ground. 20 to 30V 7
✸ Between connection BRC1, (17) and chassis ground. 20 to 30V 8

B. Open or high
Between connection R14, (3) and BRC2, (1) and (12) 0.0 to 1.0Ω 9
resistance
At connection R14, (2) and chassis ground. 0.0 to 1.0Ω 10
Resistance Ω
At connection BRC1, (8), (16) and chassis ground. 0.0 to 1.0Ω 11
Between connection R14, (1) and BRC1, (13) 0.0 to 1.0Ω 12

Remark
20-760 1 HM400-1L
HM400-1L 20-761 1

17 V



(OL) open 8
Fuses removed.
B. Short to chassis
Fuses removed.
harness
(OL) open 10
Fuses removed.

Remark
20-762 1 HM400-1L
HM400-1L 20-763 1
TROUBLESHOOTING (BK-21) FAILURE CODE [DB19KM]
(BK-21) FAILURE CODE [DB19KM]
MISTAKEN OPERATION OF RETARDER CONTROLLER (KM)

Contents Of Trouble • When the ignition switch is ON, the input connector check signal does not match the setting inside the controller.

Steps Circuit Diagnostic Procedures For Error Code [DB19KM] Specifications No. Readings

• Disconnect (BRC5A) connector from retarder controller and install T-adapter on (BRC5A) wiring harness connector only.
A. Open or high
Resistance Ω Between connector BRC5A, (1) and chassis ground. 0.0 to 1.0Ω 1
resistance

Remark
20-764 1 HM400-1L
TROUBLESHOOTING (BK-22) FAILURE CODE [DB1SKQ]
(BK-22) FAILURE CODE [DB1SKQ]
RETARDER CONTROL S-NET LINE MISMATCHED (KQ)

• The communication (S-NET) with the transmission controller is defective and it is impossible to obtain the model
selection data
Cause Remedy
With ignition switch

Is other failure code (DAFSKQ) YES Another problem is occurring at Go to
ON, operate monitor (DAQAKQ) (DAQSKR) displayed the same time troubleshooting for
or recorded at same time? Defective retarder controller displayed code
NO
Does condition become normal

Turn ignition switch ON when retarder controller is NO
replaced Defective transmission controller Replace
YES
Defective retarder controller Replace
HM400-1L 20-765 1
TROUBLESHOOTING (BK-23) FAILURE CODE [DHU2KX]
(BK-23) FAILURE CODE [DHU2KX]
ACCUMULATOR OIL PRESSURE FRONT SENSOR OUT OF RANGE (KX)

Contents Of Trouble • The voltage of the signal circuit of the front accumulator oil pressure sensor went below 0.5 V or above 4.5 V

Steps Circuit Diagnostic Procedures For Failure Code [DHU2KX] Specifications No. Readings
1. Pressure Sensor
• Disconnect (B25) connector from sensor and install T-adapter between (B25) connector and sensor.
✸ At sensor B25, between (3) and chassis ground. 0.5 to 4.5V 1

Voltage
A. Sensor test ✸ At sensor B25, between (2) and chassis ground. 20 to 30V 2
Resistance Ω At sensor B25, between (1) and chassis ground. 0.0 to 1.0Ω 3

• Disconnect (B25) connectors from sensor and isolate connector.
• Disconnect (BRC1, BRC3A and BRC3B) connector from the retarder controller and install T-adapter on (BRC1, BRC3A and BRC3B) wiring
harness connector only.
Voltage ✸ At controller BRC1, (1) and chassis ground. 20 to 30V 4
resistance Resistance Ω Between connectors B25, (2) and BRC1, (1) 0.0 to 1.0Ω 6
Between connectors B25, (3) and BRC3B, (5) 0.0 to 1.0Ω 7

B. Short to chassis
ground or within Resistance Ω At connector B25, between (1) and (2) (OL) open 10
harness

Remark
20-766 1 HM400-1L
HM400-1L 20-767 1
(BK-24) FAILURE CODE [DHU3KX]
ACCUMULATOR OIL PRESSURE REAR SENSOR OUT OF RANGE (KX)

Contents Of Trouble • The voltage of the signal circuit of the front accumulator oil pressure sensor went below 0.5 V or above 4.5 V

Steps Circuit Diagnostic Procedures For Failure Code [DHU3KX] Specifications No. Readings
1. Pressure Sensor
• Disconnect (B24) connector from sensor and install T-adapter between (B25) connected and sensor.
✸ At sensor B24, between (3) and chassis ground. 0.5 to 4.5V 1

Voltage
A. Sensor test ✸ At sensor B24, between (2) and chassis ground. 20 to 30V 2
Resistance Ω At sensor B24, between (1) and chassis ground. 0.0 to 1.0Ω 3

• Disconnect (B24) connectors from sensor and isolate connector.
• Disconnect (BRC1, BRC3A and BRC3B) connector from the retarder controller and install T-adapter on (BRC1, BRC3A and BRC3B) wiring
harness connector only.
Voltage ✸ At controller BRC1, (1) and chassis ground. 20 to 30V 4
resistance Resistance Ω Between connectors B24, (2) and BRC1, (1) 0.0 to 1.0Ω 6
Between connectors B24, (3) and BRC3B, (6) 0.0 to 1.0Ω 7

B. Short to chassis
ground or within Resistance Ω At connector B25, between (1) and (2) (OL) open 10
harness

Remark
20-768 1 HM400-1L
HM400-1L 20-769 1
TROUBLESHOOTING (BK-25) FAILURE CODE [DK51L5]
(BK-25) FAILURE CODE [DK51L5]
TROUBLE IN RETARDER LEVER POTENTIOMETER SYSTEM (KB)

• The signal voltage of the potentiometer of the retarder lever circuit went below 0.3 V or above 4.7 V, or the
Contents Of Trouble
potentiometer signal and switch signal do not match

Steps Circuit Diagnostic Procedures For Error Code [DK51L5] Specifications No. Readings

• Disconnect (RTL) connector from retarder lever and isolate retarder lever switch.
At sensor RTL, between (1) and (3) 1
At sensor RTL, between (2) and (3)

2
A. Sensor test Resistance Ω lever at mid position.
At sensor RTL, between (2) and (1)

3
lever at mid position.
At switch RTL, between (4) and (6) [see table] ⎯ 4

B. Validation switch test Resistance Ω
At switch RTL, between (5) and (6) [see table] ⎯ 5
• Disconnect (RTL) connector from retarder lever switch unit.
• Disconnect (BRC2, BRC3A, BRC3B and BRC5A) connector from retarder controller and install T-adapter on (BRC2, BRC3A, BRC3B and
BRC5A) wiring harness connector only.
Between connectors RTL, (1) and BRC2, (16) 6
Between connectors RTL, (2) and BRC3B, (16) 0.0 to 1.0Ω 7
A. Open or high Between connectors RTL, (3) and BRC3A, (16) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors RTL, (4) and BRC5A, (6) 0.0 to 1.0Ω 9
Between connectors RTL, (5) and BRC5A, (7) 0.0 to 1.0Ω 10
Between connectors RTL, (6) and chassis ground. 0.0 to 1.0Ω 11
RTL switch table Lever released Lever applied
Between (4) and (6) 0.0 to 1.0Ω (OL) open
Between (5) and (6) (OL) open 0.0 to 1.0Ω
20-770 1 HM400-1L
At connector RTL, between (1) and (2) (OL) open 12

B. Short to chassis
ground or within Resistance Ω At connector RTL, between (6) and (5) (OL) open 17
harness
At connector RTL, between (1) and chassis ground. (OL) open 18

Remark
HM400-1L 20-771 1
TROUBLESHOOTING (BK-26) FAILURE CODE [DK52KX]
(BK-26) FAILURE CODE [DK52KX]
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KX)

Contents Of Trouble • The voltage of potentiometer 1 signal circuit or potentiometer 2 signal circuit went below 0.3 V or above 4.7 V.

1. Dump Lever Switch

• Disconnect (HSL) connector from dump lever and isolate dump lever.
• Disconnect (LKO) connector from resistor and isolate resistor.
At switch HSL, between (1) and (4) 1
A. Dump lever switch At switch HSL, between (2) and (4) 3

Resistance Ω
test At switch HSL, between (3) and (4) 3
At resistor LKO, between (1) and (2) 39 to 45Ω 4
At resistor LKO, between (1) or (2) and chassis ground. (OL) open 5
• Disconnect (HSL and LKO) connectors from dump lever and isolate connectors.
• Disconnect (BRC1, BRC3A and BRC3B) connector from the retarder controller and install T-adapter on (BRC1, BRC3A and BRC3B)
wiring harness connector only.
Between connectors HSL, (1) and BRC3A, (16) 0.0 to 1.0Ω 6

Between connectors HSL, (2) and BRC3B, (14) 0.0 to 1.0Ω 7
A. Open or high Between connectors HSL, (3) and BRC3B, (12) 0.0 to 1.0Ω 8
Resistance Ω
resistance Between connectors HSL, (4) and BRC3A, (6) 0.0 to 1.0Ω 9
Between connectors LKO, (1) and BRC1, (11) 0.0 to 1.0Ω 10
Between connectors LKO, (2) and chassis ground. 0.0 to 1.0Ω 11
At connector HSL, between (1) and chassis ground. (OL) open 12

B. Short to chassis At connector HSL, between (4) and chassis ground. (OL) open 15
harness At connector LKO, between (1) and (2) (OL) open 16
At connector HSL, between (1) and (2), (3), (4) (OL) open 17
At connector HSL, between (2) and (3), (4) (OL) open 18

At connector HSL, between (3) and (4) (OL) open 19

Remark
20-772 1 HM400-1L
HM400-1L 20-773 1
(BK-27) FAILURE CODE [DK53L8]
DUMP LEVER INPUT SIGNAL OUT OF RANGE (L8)

Contents Of Trouble • The voltage of potentiometer 1 signal circuit or potentiometer 2 signal circuit went below 0.3 V or above 4.7 V.



Resistance Ω

Resistance Ω



Remark
20-774 1 HM400-1L
HM400-1L 20-775 1
BODY POSITION SENSOR SIGNAL OUT OF RANGE (KX)

Contents Of Trouble • The total voltage of potentiometer 1 signal circuit and potentiometer 2 signal circuit went below 4.4 V or above 5.6 V

1. Body Position Sensor

• Disconnect (B34) connector from sensor and isolate sensor.
At sensor B34, between (1) and (3) 1

A. Sensor test Resistance Ω At sensor B34, between (1) and (2) 2
At sensor B34, between (2) and (3) 3

• Disconnect (B34) connectors from sensor and isolate connectors.
• Disconnect (BRC3A and BRC3B) connector from the retarder controller and install T-adapter on (BRC3A and BRC3B) wiring harness
connector only.
A. Open or high
Resistance Ω Between connectors B34, (2) and BRC3B, (13) 0.0 to 1.0Ω 5
resistance

B. Short to chassis
ground or within Resistance Ω At connector B34, between (3) and chassis ground. (OL) open 9
harness
At connector B34, between (1) and (2), (3) (OL) open 10

Remark
20-776 1 HM400-1L
HM400-1L 20-777 1
TROUBLESHOOTING (BK-29) FAILURE CODE [DLF4KA]
(BK-29) FAILURE CODE [DLF4KA]
TRANSMISSION OUTPUT SHAFT “F” SPEED SENSOR OUT OF RANGE (KA)

Contents Of Trouble • A Open has occurred in the signal circuit of the transmission output shaft F speed sensor and the signal is not input

1. Output Shaft Speed Sensor

• Disconnect (DT2-2) connector from sensor and isolate sensor.
A. Solenoid and switch At sensor DT2-2, between (1) and (2) 500 to 1000Ω 1
Resistance Ω
test At sensor DT2-2, between (1) or (2) and chassis ground. (OL) open 2

• Disconnect (DT2-2) connectors from sensor and isolate connector.
A. Open or high Between connectors DT2-2, (1) and BRC3A, (12) 0.0 to 1.0Ω 3
Resistance Ω
resistance Between connectors DT2-2, (2) and BRC3A, (14) 0.0 to 1.0Ω 4
B. Short to chassis
harness

Remark
20-778 1 HM400-1L
TROUBLESHOOTING (BK-30) FAILURE CODE [DLT3KA]
(BK-30) FAILURE CODE [DLT3KA]
TRANSMISSION OUTPUT SHAFT “R” SPEED SENSOR OUT OF RANGE (KA)

Contents Of Trouble • A Open has occurred in the signal circuit of the transmission output shaft R speed sensor and the signal is not input

Steps Circuit Diagnostic Procedures For Failure Code [DLT3KA] Specifications No. Readings
1. Output Shaft Speed Sensor
A. Solenoid and switch At sensor N3, between (1) and (2) 500 to 1000Ω 1
Resistance Ω
test At sensor N3, between (1) or (2) and chassis ground. (OL) open 2
• Disconnect (N3) connectors from sensor and isolate connector.
• Disconnect (BRC3A and ATC3A) connector from the retarder controller and install T-adapter on (BRC3A and ATC3A) wiring harness
connector only.
A. Open or high
Resistance Ω Between connectors N3, (2) and ATC3A, (14) 0.0 to 1.0Ω 4
resistance
Between connectors N3, (1) and BRC3A, (13) 0.0 to 1.0Ω 5
At connector N3, between (1) and chassis ground. (OL) open 6
B. Short to chassis
ground or within Resistance Ω At connector N3, between (2) and chassis ground. (OL) open 7
harness
Remark
HM400-1L 20-779 1
TROUBLESHOOTING (BK-30) FAILURE CODE [DLT3KA]
20-780 1 HM400-1L
TROUBLESHOOTING (BK-31) FAILURE CODE [DW71KZ]
(BK-31) FAILURE CODE [DW71KZ]
EXHAUST BRAKE SOLENOID OPEN OR SHORTED (KZ)

• When output is sent to the exhaust brake solenoid circuit, excessive electric current flows; when there is output, no
Contents Of Trouble
electric current flows; when the output is OFF, electric current flows

Steps Circuit Diagnostic Procedures For Failure Code [DW71KZ] Specifications No. Readings
1. Exhaust Brake Solenoid

• Disconnect (B29) connector from solenoid and isolate solenoid.
At solenoid B29, between (1) and (2) 20 to 60Ω 1
A. Solenoid test Resistance Ω
At solenoid B29, between (1) or (2) and chassis ground. (OL) open 2

• Disconnect (B29) connector from solenoid and isolate connector.
• Disconnect (BRC1) connector from retarder controller and install T-adapter on (BRC1) wiring harness connector only.
A. Short to Between connector B29, (1) and chassis ground. (OL) open 3
or within harness At connector B29, between (1) and (2) (OL) open 4
B. Open or high Between connectors B29, (1) and BRC1, (3) 0.0 to 1.0Ω 5
Between connector B29, (2) and chassis ground. 0.0 to 1.0Ω 6

Remark
HM400-1L 20-781 1
DUMP LEVER INPUT SIGNAL OUT OF RANGE (KZ)

• When output is sent to the dump lever kick-out solenoid circuit, excessive electric current flows; when there is output,
Contents Of Trouble
no electric current flows; when the output is OFF, electric current flows


Resistance Ω
Resistance Ω
Remark
20-782 1 HM400-1L
HM400-1L 20-783 1
(BK-33) FAILURE CODE [DW73KZ]
DUMP SELECTOR VALVE OPEN OR SHORTED (KZ)

• When output is sent to the dump selector valve solenoid circuit, excessive electric current flows; when there is output,
Contents Of Trouble
no electric current flows; when the output is OFF, electric current flowss

Steps Circuit Diagnostic Procedures For Failure Code [DW73KZ] Specifications No. Readings
1. Dump Pilot Valve

• Disconnect (B31) connector from dump pilot valve and isolate dump pilot valve.
At valve B31, between (1) and (2) 15 to 35Ω 1
A. Dump pilot valve At switch B32, between (1) and (2) 5 to 20Ω 2
Resistance Ω
test At resistor B31, between (1) or (2) and chassis ground. (OL) open 3
At resistor B32, between (1) or (2) and chassis ground. (OL) open 4

• Disconnect (B31 and B32) connectors from dump pilot valves and isolate connectors.
Between connectors B31, (1) and BRC1, (12) 0.0 to 1.0Ω 5
A. Open or high Between connectors B31, (2) and chassis ground. 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connectors B32, (1) and BRC2, (10) 0.0 to 1.0Ω 7

B. Short to
chassis ground Resistance Ω At connector B32, between (2) and chassis ground. (OL) open 11
or within harness
3. Retarder And Retarder Controller Units

Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Retarder or Retarder
20-784 1 HM400-1L
HM400-1L 20-785 1
TROUBLESHOOTING (BK-34) FAILURE CODE [DX11KA]
(BK-34) FAILURE CODE [DX11KA]
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KA)

Contents Of Trouble • When output is sent to the rear brake pressure reducing valve solenoid circuit, no electric current flows

Steps Circuit Diagnostic Procedures For Failure Code [DX11KA] Specifications No. Readings
1. Rear Brake Solenoid



Remark
20-786 1 HM400-1L
TROUBLESHOOTING (BK-35) FAILURE CODE [DX11KB]
(BK-35) FAILURE CODE [DX11KB]
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KB)

Contents Of Trouble • When output is sent to the rear brake pressure reducing valve solenoid circuit, excessive electric current flows

Steps Circuit Diagnostic Procedures For Failure Code [DX11KB] Specifications No. Readings



Remark
HM400-1L 20-787 1
TROUBLESHOOTING (BK-36) FAILURE CODE [DX11KY]
(BK-36) FAILURE CODE [DX11KY]
REAR BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED (KY)

Contents Of Trouble • When the output to the rear brake pressure reducing valve solenoid circuit is OFF, electric current flows

Steps Circuit Diagnostic Procedures For Failure Code [DX11KY] Specifications No. Readings



Remark
20-788 1 HM400-1L
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED

(KA)
Contents Of Trouble • When output is sent to the front brake pressure reducing valve solenoid circuit, no electric current flows





Remark
HM400-1L 20-789 1
FRONT BRAKE PRESSURE REDUCING SOLENOID OPEN OR SHORTED

(KB)
Contents Of Trouble • When output is sent to the front brake pressure reducing valve solenoid circuit, excessive electric current flows





Remark
20-790 1 HM400-1L
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KA)

Contents Of Trouble • When output is sent to the dump EPC valve solenoid circuit, no electric current flows

1. Dump Pilot Valve
Resistance Ω
Resistance Ω
B. Short to
or within harness
Remark
HM400-1L 20-791 1
20-792 1 HM400-1L
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KB)

Contents Of Trouble • When output is sent to the dump EPC valve solenoid circuit, excessive electric current flowss

1. Dump Pilot Valve

Resistance Ω

Resistance Ω


B. Short to
or within harness

Remark
HM400-1L 20-793 1
20-794 1 HM400-1L
(BK-41) FAILURE CODE [DX13KY]
DUMP EPC VALVE SOLENOID OPEN OR SHORTED (KY)

Contents Of Trouble • When output is sent to the dump EPC valve solenoid circuit is OFF, excessive electric current flows

Steps Circuit Diagnostic Procedures For Failure Code [DX13KY] Specifications No. Readings
1. Dump Pilot Valve

Resistance Ω

Resistance Ω


B. Short to
or within harness

Remark
HM400-1L 20-795 1
20-796 1 HM400-1L
TROUBLESHOOTING (BK-42) FAILURE CODE [DX14KZ]
(BK-42) FAILURE CODE [DX14KZ]
REAR DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ)

• When output is sent to the rear differential lock solenoid circuit, excessive electric current flows; when there is
Contents Of Trouble
output, no electric current flows; when the output is OFF, electric current flows

Steps Circuit Diagnostic Procedures For Failure Code [DX14KZ] Specifications No. Readings



Remark
HM400-1L 20-797 1
(BK-43) FAILURE CODE [DX15KZ]
FRONT DIFFERENTIAL LOCK SOLENOID OPEN OR SHORTED (KZ)

• When output is sent to the front differential lock solenoid circuit, excessive electric current flows; when there is
Contents Of Trouble
output, no electric current flows; when the output is OFF, electric current flows

Steps Circuit Diagnostic Procedures For Failure Code [DX15KZ] Specifications No. Readings



Remark
20-798 1 HM400-1L
HM400-1L 20-799 1
TROUBLESHOOTING (BK-44) NO FAILURE CODE DISPLAYED
(BK-44) NO FAILURE CODE DISPLAYED
PARKING BRAKE SYSTEM FAILURE

• Nature of failure: The parking brake does not work properly (no failure code is displayed)
Contents Of Trouble • Before starting troubleshooting, check that fuse BT2-6 is normal (if the fuse is blown, there has probably been a surge
of current caused by a short circuit, so check the related circuits).

Steps Circuit Diagnostic Procedures For Failure Code [NONE] Specifications No. Readings
1. P{arking Brake Safety Relay

A. Relay check ⎯ Does system work properly now? ⎯ 2 Yes or No

2. Parking Brake Solenoid

3. ACC Oil Pressure Switches
• Disconnect (B20 and B21) connector from oil pressure switch and isolate switch.

• Disconnect (R33) connector from manual switch and isolate connector.
• Disconnect (B20 and B21) connectors ACC oil pressure switches and isolate connectors.
• Disconnect (B14) connector from parking brake solenoid and isolate connector.
A. Short to Between connection B20, (1) and chassis ground. (OL) open 11
chassis ground Resistance Ω Between connection B20, (2) and chassis ground. (OL) open 12
or within harness
Between connection R33, (3) and chassis ground, fuse

(OL) open 14
removed.
20-800 1 HM400-1L
TROUBLESHOOTING (BK-44) NO FAILURE CODE DISPLAYED

Voltage
Between connection R33, (1) and R19, (1), (3) 0.0 to 1.0Ω 17
B. Open or high Between connection R33, (2) and B21, (1) 0.0 to 1.0Ω 18
resistance Between connection R19, (2) and chassis ground. 0.0 to 1.0Ω 19
Resistance Ω
Between connection B14, (2) and chassis ground. 0.0 to 1.0Ω 20
Between connection B14, (1) and B20, (2) 0.0 to 1.0Ω 21
Between connection B20, (1) and B21, (2) 0.0 to 1.0Ω 22

Remark
HM400-1L 20-801 1
TESTING AND ADJUSTING (BK-44) NO FAILURE CODE DISPLAYED
20-802 HM400-1L
TROUBLESHOOTING MACHINE MONITOR
PANEL SYSTEM (MON MODE)

MON CONTROL SYSTEM CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
(MON-1) FAILURE CODE [B@C6NS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
FRONT BRAKE OIL OVERHEAT CONDITION (NS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
REAR BRAKE OIL OVERHEAT CONDITION (NS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
CENTER BRAKE OIL OVERHEAT CONDITION (NS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-921
(MON-4) FAILURE CODE [B@CENS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-921
TORQUE CONVERTER OIL IS IN OVERHEAT CONDITION (NS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-921
(MON-5) FAILURE CODE [DAF0KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM) . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
(MON-6) FAILURE CODE [DAF9KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-924
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM) . . . . . . . . . . . . . . . . . . . . . . . . . 20-924
(MON-7) FAILURE CODE [DAFSKQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
MODEL SELECTION DOES NOT MATCH (KQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-925
(MON-8) FAILURE CODE [DAQSKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-926
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR) . . . . . . . . . . . . . . . . . . . . . . 20-926
(MON-9) FAILURE CODE [DA1SKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-928
(MON-10) FAILURE CODE [DA2SKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-930
(MON-11) FAILURE CODE [DV00KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-932
DEFECTIVE ALARM BUZZER (KB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-932
(MON-12) NO FAILURE CODE DISPLAYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-934
WITH IGNITION KEY “ON” NO DISPLAY IS SHOWN ON MONITOR PANEL . . . . . . . . . . . . . . . . 20-934
WITH IGNITION KEY “OFF” NO DISPLAY IS SHOWN ON MONITOR PANEL . . . . . . . . . . . . . . . . 20-936
ALARM BUZZER DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-938
INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL . . . . . . . . . . . . . . . . 20-940
ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED . . . . . . . . . . . . . . . . . 20-941
MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE . . . . . . . . . . . . . . . . . . . . 20-943
POWER MODE SWITCH DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-945
AISS FUNCTION DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-947
RIGHT AND LEFT DIFFERENTIAL LOCK SWITCH DOES NOT WORK PROPERLY . . . . . . . . . . . 20-949
LEFT AND RIGHT DIFFERENTIAL PEDAL LOCK SYSTEM DOES NOT WORK PROPERLY . . . . 20-951
HM400-1L 20-901 1
INNER AXLE DIFFERENTIAL LOCK SYSTEM DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . 20-953
EXHAUST BRAKE DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-955
SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-957
SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-959
HEAD AND TAIL LAMPS DO NOT WORK PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-962
20-902 1 HM400-1L
HM400-1L 20-903 1
20-904 1 HM400-1L
HM400-1L 20-905 1
20-906 1 HM400-1L
HM400-1L 20-907 1
20-908 1 HM400-1L
TROUBLESHOOTING MON CONTROL SYSTEM CIRCUIT DIAGRAM
MON CONTROL SYSTEM CIRCUIT DIAGRAM
HM400-1L 20-909 1
20-910 1 HM400-1L
12
HM400-1L 20-911 1
20-912 1 HM400-1L
HM400-1L 20-913 1
20-914 1 HM400-1L
12
MEMORANDUM
HM400-1L 20-915 1
Front brake oil: Overheat Front brake cooling oil is over- • Front brake cooling oil is overheated
B@C6NS
(NS) heated (when system is working normally)
(MON-1)
• Defective machine monitor
Rear brake oil: Overheat Rear brake cooling oil is overheated • Rear brake cooling oil is overheated
B@C7NS
(NS) (when system is working normally)
(MON-2)
Center brake oil: Overheat Centre brake cooling oil is over- • Centre brake cooling oil is overheated
B@C8NS
(NS) heated (when system is working normally)
(MON-3)
Torque converter: Overheat Torque converter is overheated • Torque converter oil is overheated
B@CENS
(NS) (when system is working normally)
(MON-4)
Monitor panel: Mistaken Option setting of rotary switch at • Defective setting of rotary switch, dip
operation or mistaken setting rear of machine monitor and dip switch, or option connector (when sys-
DAFOKM (KM)) switches does not match signal tem is working normally)
(MON-5) from option setting connector • Open or short circuit in r circuit wiring
harness
Monitor panel: Mistaken Check signal of connector does not • Mistaken connection of connector
operation or mistaken setting match internal setting of machine DPC2 (A, B) and connector DPC3 (A,
DAF9KM (KM)) monitor B) (when system is working normally)
(MON-6) • Open or short circuit with chassis
ground in signal 1 circuit wiring harness
Monitor panel: Monitor panel: Communication (S-NET) with trans- • Open or short circuit with chassis
Non match in model selec- mission controller is defective and ground, or short circuit with power
DAFSKQ tion signal (KQ) model selector information cannot source in S-NET circuit wiring harness
(MON-7) be received, or setting of transmis- • Defective transmission controller
sion controller rotary switch is not • Defective machine monitor
correct
Transmission controller S- S-NET data cannot be received • Open or short circuit with chassis
NET: Defective communica- from transmission controller ground, or short circuit with power
DAQSKR tion, abnormality in corre- source in S-NET (+) circuit wiring har-
(MON-8) sponding component system ness
(KR) • Defective transmission controller
Retarder controller (q1) S- S-NET data cannot be received • Open or short, short circuit with chassis
NET: Defective communica- from retarder controller ground, or short circuit with power
DB1SKR tion, abnormality in corre- source in S-NET (+) circuit wiring har-
(MON-9) sponding component system ness
(KR) • Defective retarder controller (❋)
Engine controller S-NET: Unable to receive S-NET informa- • Wiring harness in S-NET (+) circuit dis-
Defective communication, tion from engine controller connected or connected defectively or
DB2SKR abnormality in corresponding short-circuit
(MON-10) component system (KR) • Engine controller faulty
• Machine monitor faulty
Alarm buzzer: Short-circuit Alarm buzzer output circuit short- • Alarm buzzer faulty
DV00KB (KB) circuit • Wiring harness in alarm buzzer output
(MON-11) circuit short-circuit
• Machine monitor faulty
❋ The code (MON-**) given below the failure code is the troubleshooting number
20-916 1 HM400-1L
Action
Code
• Takes no action • If machine continues to be used as it
is, there is danger that front brake E02
will break
is, there is danger that rear brake will E02
break
is, there is danger that centre brake E02
will break
is, there is danger that torque con- E02
verter will break
• Wiring harness resistance value • Holds abnormal condition until igni- • Some functions (options) do not
DPC3A (female) tion switch is turned OFF work
(4)(6)(7)(13)(14)(15) - ground • Does not recognize functions (op-
• When connector is connected: tions) where setting does not match E03
Max. 1 W • Does not record as trouble data
• When connector is discon-
nected: Min. 1 MW
• Signal voltage • Holds abnormal condition until igni-
DPC2A (female) (5) - ground: tion switch is turned OFF
20 - 30 V • Does not record as trouble data
E03
• Holds abnormal condition until igni- • No meters or gauges give display

tion switch is turned OFF • Some panel switches and lamps do
• Controls as HM400 not work
E03
• S-NET voltage • Holds condition existing when prob- • Meters, gauges, cautions, special
Between DPC4 (1)(2) and (4)(5): lem occurred function receiving data from trans-
6-9V mission controller do not work or E03
Between ATC4 (6)(12) and (10): give any display
6-9V
• S-NET voltage • Holds condition existing when prob- • Cautions, special function receiving
Between DPC4 (1)(2) and (4)(5): lem occurred data from retarder controller (q1) do
6-9V not work or give any display E03
Between ATC4 (6)(12) and (10):
6-9V
• S-NET voltage • Holds condition existing when prob- • Cautions, special function receiving
• Between DPC4 (1)(2) and (4)(5): lem occurred data from engine controller do not
6-9V work or give any display E03
• Between CN2 (8)(18) and (6):
6-9V
• Output circuit voltage • Holds abnormal condition until igni- • Alarm buzzer does not sound
DPC1 (13) - (9)(10): When tion switch is turned OFF
buzzer is stopped: 20 - 30 V. • Turns buzzer output circuit OFF E01
When buzzer is sounding: 1 V
★ MON-12 through 25 not shown in this chart.
HM400-1L 20-917 1

● Failure.
Contents Of Trouble ● Failure code displayed.
● Additional information.
● Digital Volt Ohm Meter. T-adapter kit.

● Do not mark on original page of service manual. Remove this page from the service manual and make a copy for
recording information
● If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on
the right of the procedure.
● Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless
otherwise instructed to in the
Your
or Voltage Your
information
2. Diode Test
Your
resistance or Voltage Your
information
Your
ground or within
or Voltage Your
harness Test procedure for harness. (connector) to (connector) readings 7
information
Resistance Ω Your
20-918 1 HM400-1L

HM400-1L 20-919 1
TROUBLESHOOTING (MON-1) FAILURE CODE [B@C6NS]
12
(MON-1) FAILURE CODE [B@C6NS]
FRONT BRAKE OIL OVERHEAT CONDITION (NS)

★ The front brake cooling oil is overheating.
Cause Remedy
NO
Defective machine monitor Repair
Stop engine Is front brake oil overheated?
Carry out trouble-

YES The oil is overheated shooting of the front
brake system
REAR BRAKE OIL OVERHEAT CONDITION (NS)

★ The rear brake cooling oil is overheating
Cause Remedy
NO
Stop engine Is rear brake oil overheated?
Carry out trouble-

YES The oil is overheated shooting of the rear
brake system
20-920 1 HM400-1L
TROUBLESHOOTING (MON-3) FAILURE CODE [B@C8NS]
CENTER BRAKE OIL OVERHEAT CONDITION (NS)

★ The center brake cooling oil is overheating.
Cause Remedy
NO
Stop engine Is center brake oil overheated?
Carry out trouble-

YES The oil is overheated shooting of the center
brake system
(MON-4) FAILURE CODE [B@CENS]
TORQUE CONVERTER OIL IS IN OVERHEAT CONDITION (NS)

★ The torque converter oil is overheating
Cause Remedy
NO
Is torque converter oil

Stop engine
overheated?
Carry out trouble-

YES The oil is overheated shooting of the torque
converter system
HM400-1L 20-921 1
TROUBLESHOOTING (MON-5) FAILURE CODE [DAF0KM]
(MON-5) FAILURE CODE [DAF0KM]
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)
Contents Of Trouble
● The option setting of the rotary switch at the rear of the machine monitor and dip switches does
not match the signal from the option setting connector

Steps Circuit Diagnostic Procedures For Action Code [E03] Specifications No. Readings
Dip Switches ⎯ Check setting on dip switches first Setting correct? 1 Yes or No

• Disconnect monitor controller (DPC3A) and install T-adapter on wiring harness only.
Between connector DPC3A, (4) and chassis ground. 0.0 to 1.0Ω 2
A. Open or high Between connector DPC3A, (7) and chassis ground. 0.0 to 1.0Ω 4
Resistance Ω
resistance Between connector DPC3A, (13) and chassis ground. 0.0 to 1.0Ω 5
2. Monitor Controller Unit

Remark
If all test results fall within the specifications listed above in the testing procedures, the error may be in your Monitor Controller Unit.
20-922 1 HM400-1L
HM400-1L 20-923 1
(MON-6) FAILURE CODE [DAF9KM]
MISTAKEN OPERATION OR SETTING IN MONITOR PANEL (KM)

● The check signal of the connector does not match the internal setting of the machine monitor.
Contents Of Trouble Before starting troubleshooting, check that fuse BT2-2 is normal (if the fuse is blown, there has
probably been a surge of current caused by a short circuit, so check the related circuits).

Fuse Check ⎯ Check fuse (BT2-2) Fuse good? 1 Yes or No

• Disconnect monitor controller (DPC2A) and install T-adapter between wiring harness connector and monitor controller (DPC2A).
A. Open or high
Voltage At connector DPC2A, (5) and chassis ground. 20 to 30V 2
resistance

Remark
20-924 1 HM400-1L
TROUBLESHOOTING (MON-7) FAILURE CODE [DAFSKQ]
12
(MON-7) FAILURE CODE [DAFSKQ]
MODEL SELECTION DOES NOT MATCH (KQ)
★ Communication (S-NET) with the transmission controller is defective and the model selector information cannot be
received, or the setting of the transmission controller rotary switch is not correct
Cause Remedy
Turn ignition switch to the Is other failure code

“ON position. [DAQAKQ] also displayed at NO
Operate machine monitor. the same time?
YES Defective S-NET communication

circuit between machine monitor Repair or replace
and transmission controller
When troubleshooting for

failurecode [DAQSKR] is
carried out, iscondition normal Other problem may be occurring
(S-NETcommunication circuit NO Go to troubleshooting
at same time.
betweenmachine monitor and
transmissioncontroller)?
YES
Turn ignition switch to the Does condition become normal

when machine monitor is NO Defective transmission controller Replace
“ON” position.
replaced?
YES
Defective machine controller Replace
HM400-1L 20-925 1
TROUBLESHOOTING (MON-8) FAILURE CODE [DAQSKR]
(MON-8) FAILURE CODE [DAQSKR]
DEFECTIVE COMMUNICATION IN CORRESPONDING SYSTEM (KR)
● The S-NET data cannot be received from the transmission controller. Check that the continuity
Contents Of Trouble of the junction
connectors (JCB, JCC, JCD, JCE, JCF, JCG) is normal.

• Disconnect transmission controller (ATC4) and install T-adapter on wiring harness only.
• Disconnect retarder controller (BRC4) and install T-adapter on wiring harness only.
• Disconnect engine controller (CN2) and install T-adapter on wiring harness only.
• Disconnect monitor controller (DPC4) and install T-adapter on wiring harness only.
Between connector DPC4, (1) and BRC4, (12) 0.0 to 1.0Ω 1
Between connector DPC4, (1) and ATC4, (12) 0.0 to 1.0Ω 2
Between connector DPC4, (1) and CN2, (18) 0.0 to 1.0Ω 3
A. Open or high Between connector DPC4, (2) and CN2, (8) 0.0 to 1.0Ω 6
Resistance Ω
resistance Between connector DPC4, (4) and BRC4, (10) 0.0 to 1.0Ω 7

At connector DPC4, (1) and chassis ground. (OL) open 13

B. Short to At connector DPC4, (2) and chassis ground. (OL) open 14
or within harness At connector DPC4, (4) and chassis ground. (OL) open 15

Remark
20-926 1 HM400-1L
TROUBLESHOOTING (MON-8) FAILURE CODE [DAQSKR]
HM400-1L 20-927 1
TROUBLESHOOTING (MON-9) FAILURE CODE [DA1SKR]
(MON-9) FAILURE CODE [DA1SKR]

Resistance Ω



Remark
20-928 1 HM400-1L
HM400-1L 20-929 1
(MON-10) FAILURE CODE [DA2SKR]

Resistance Ω



Remark
20-930 1 HM400-1L
HM400-1L 20-931 1
TROUBLESHOOTING (MON-11) FAILURE CODE [DV00KB]
(MON-11) FAILURE CODE [DV00KB]
DEFECTIVE ALARM BUZZER (KB)

● A short circuit with the power source has occurred in the output circuit of the alarm buzzer
Before starting
Contents Of Trouble
troubleshooting, check that fuse BT2-2 is normal (if the fuse is blown, there has probably been
a surge of current caused by a short circuit, so check the related circuits).

1. Right Rear Brake Warning Switch

• Disconnect (BZ2) connector from buzzer and isolate buzzer.
At buzzer BZ2, between (1) and (2) 2

At buzzer BZ2, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect (BZ2) connectors from buzzer and isolate connector.
• Disconnect (DPC1) connector from the monitor controller and install T-adapter on (DPC1) wiring harness connector only.
Voltage ✸ Between connector BZ2, (1) and chassis ground. 20 to 30V 4

A. Open or high
Between connectors DPC1, (13) and BZ2, (2) 0.0 to 1.0Ω 5
Between connector DPC1, (9), (10) and chassis ground. 0.0 to 1.0Ω 6
B. Short to chassis
ground or within Resistance Ω At connector DPC1, between (13) and chassis ground. (OL) open 7
harness

Remark
20-932 1 HM400-1L
TROUBLESHOOTING (MON-11) FAILURE CODE [DV00KB]
HM400-1L 20-933 1
TROUBLESHOOTING (MON-12) NO FAILURE CODE DISPLAYED
(MON-12) NO FAILURE CODE DISPLAYED
WITH IGNITION KEY “ON” NO DISPLAY IS SHOWN ON MONITOR PANEL

Contents Of Trouble ● Monitor is blank.

Steps Circuit Diagnostic Procedures Specifications No. Readings
Fuse Check ⎯ Check fuses (BT2-2, BT2-20 and BT2-22) condition Fuses OK? 1 Yes or No


• Disconnect (DPC1) connector from monitor controller and install T-adapter on (DPC1) wiring harness connector only.
✸ Between connector DPC1, (4) and chassis ground. 20 to 30V 3

Voltage
A. Open or high ✸ Between connector DPC1, (6) and chassis ground. 20 to 30V 5
resistance ✸ Between connector DPC1, (7) and chassis ground. 20 to 30V 6
Between connectors DPC1, (9) and chassis ground. 0.0 to 1.0Ω 7

Resistance Ω

Remark
20-934 1 HM400-1L
HM400-1L 20-935 1
WITH IGNITION KEY “OFF” NO DISPLAY IS SHOWN ON MONITOR PANEL

Contents Of Trouble ● Monitor is blank.

Fuse Check ⎯ Check fuses (BT2-2, BT2-20 and BT2-22) condition Fuses OK? 1 Yes or No


• Disconnect (DPC1) connector from monitor controller and install T-adapter on (DPC1) wiring harness connector only.

Voltage
A. Open or high ✸ Between connector DPC1, (6) and chassis ground. 20 to 30V 5
resistance ✸ Between connector DPC1, (7) and chassis ground. 20 to 30V 7

Resistance Ω

Remark
20-936 1 HM400-1L
HM400-1L 20-937 1
ALARM BUZZER DOES NOT SOUND

Contents Of Trouble ● Buzzer does not work.

1. Caution Buzzer
• Disconnect (BZ2) connector from buzzer and isolate buzzer.
At buzzer BZ2, between (1) and (2) 2

A. Buzzer test Resistance Ω
At buzzer BZ2, between (1) or (2) and chassis ground. (OL) open 3

• Disconnect (BZ2) connectors from buzzer and isolate connector.
• Disconnect (DPC1) connector from the monitor controller and install T-adapter on (DPC1) wiring harness connector only.
Voltage ✸ Between connector BZ2, (1) and chassis ground. 20 to 30V 4

A. Open or high
Between connectors DPC1, (13) and BZ2, (2) 0.0 to 1.0Ω 5
Between connector DPC1, (9), (10) and chassis ground. 0.0 to 1.0Ω 6
B. Short to chassis
ground or within Resistance Ω At connector DPC1, between (13) and chassis ground. (OL) open 7
harness

Remark
20-938 1 HM400-1L
HM400-1L 20-939 1
12
INCORRECT DISPLAY OF CHARACTERS OR LAMPS ON MONITOR PANEL

★ Gauge display is different from condition of machine.
Cause Remedy
With ignition switch in Does gauges work normally when

machine monitor check switch is NO Defective machine monitor Replace
operated?
YES
Turn ignition switch When input condition of Defective signal system or

Replace
“ON” and operate applicable signal is monitored, is NO sensor
machine monitor. it found to be normal?
YES
Replace
Defective machine monitor
★ Caution lamp display is different from condition of machine.
Cause Remedy
With ignition switch in Do lamps light up and go off when

machine monitor check switch is NO Defective machine monitor Replace
operated?
YES
Turn ignition switch When input condition of Defective signal system or

Replace
“ON” and operate applicable signal is monitored, it NO sensor
machine monitor. is found to be normal?
YES
Replace
★ Nothing is displayed on character display, or display is not correct
When machine monitor check Replace

switch is operated is display NO Defective machine monitor
normal?
YES
Replace
20-940 1 HM400-1L
ACTUATION CHECK OF MACHINE MONITOR CANNOT BE PERFORMED
Contents Of Trouble ● Even when the machine monitor check switch is pressed, no lamps or gauges work, or
even when the machine monitor check switch is released, all the lamps stay ON.

1. Monitor Check Switch

• Disconnect (CK1) connector from check switch and isolate switch.
At switch CK1, between (3) and (6), switch released. (OL) open 2
A. Check switch Resistance Ω At switch CK1, between (3) and (6), switch pressed. 0.0 to 1.0Ω 3
At switch CK1, between (3) or (6) and chassis ground. (OL) open 4
• Disconnect (CK1) connector from monitor check switch and isolate connectors.
• Disconnect (DPC2A) connector from the monitor controller and install T-adapter on (DPC2A) wiring harness connector only.
A. Open or high Voltage ✸ Between connector CK1, (3) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors CK1, (6) and DPC2A, (10) 0.0 to 1.0Ω 6
B. Short to chassis At connector CK1, between (6) and chassis ground. (OL) open 7
harness At connector CK1, between (3) and (6) (OL) open 8

Remark
HM400-1L 20-941 1
20-942 1 HM400-1L
MACHINE MONITOR SELECT SWITCHES 1 OR 2 WILL NOT OPERATE
Contents Of Trouble ● Even when the machine monitor switches 1 or 2 are operated nothing happens.

Fuse Check ⎯ Check fuse (BT2-2 and BT2-22) Fuse good? 1 Yes or No
1. Monitor Mode Switch

• Disconnect (CH1) connector from mode switch 1 and isolate switch.
At switch CH1, between (2) and (3), switch in [U] 0.0 to 1.0Ω 2
At switch CH1, between (2) and (3), switch in neutral. (OL) open 3
At switch CH1, between (1) and (3), switch in [u] 0.0 to 1.0Ω 5
A. Mode switches Resistance Ω
At switch CH2, between (2) and (3), switch in [>] 0.0 to 1.0Ω 6
At switch CH2, between (1) and (3), switch in [<] 0.0 to 1.0Ω 9

• Disconnect (CH1 and CH2) connectors from mode 1 &2 switches and isolate connectors.
✸ Between connector CH1, (3) and chassis ground. 20 to 30V 10

Voltage
✸ Between connector CH2, (3) and chassis ground. 20 to 30V 11
A. Open or high Between connectors CH1, (1) and DPC2A, (14) 0.0 to 1.0Ω 12
resistance Between connectors CH1, (2) and DPC2A, (8) 0.0 to 1.0Ω 13
Resistance Ω
Between connectors CH2, (2) and DPC2A, (6) 0.0 to 1.0Ω 14
Between connectors CH2, (1) and DPC2A, (15) 0.0 to 1.0Ω 15
HM400-1L 20-943 1
Fuse Check ⎯ Check fuse (BT2-2 and BT2-22) Fuse good? 1 Yes or No
1. Monitor Mode Switch

At connector CH1, between (1) and chassis ground. (OL) open 16

B. Short to chassis At connector CH2, between (2) and chassis ground. (OL) open 19
harness At connector CH1, between (1) and (2) (OL) open 20
At connector CH2, between (1) and (2) (OL) open 21
At connector CH1, between (3) and (1), (2) (OL) open 22
At connector CH2, between (3) and (1), (2) (OL) open 23

Remark
20-944 1 HM400-1L
POWER MODE SWITCH DOES NOT WORK PROPERLY
● Even when the power mode selection switch is operated, the power mode switching function
Contents Of Trouble does not work normally, or the power mode pilot lamp does not light up and go out normally
(no failure code is displayed).

1. Power Mode Switch

• Disconnect (PWM) connector from power mode switch and isolate switch.
At switch PWM, between (1) and (3), switch UP. (OL) open 2
A. Mode switch Resistance Ω At switch PWM, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 3
At switch PWM, between (1) or (3) and chassis ground. (OL) open 4

• Disconnect (PWM) connector from power mode switch and isolate connectors.
A. Open or high Voltage ✸ Between connector PWM, (1) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors PWM, (3) and DPC2A, (13) 0.0 to 1.0Ω 6
B. Short to chassis At connector PWM, between (3) and chassis ground. (OL) open 7
harness At connector PWM, between (1) and (3) (OL) open 8

Remark
HM400-1L 20-945 1
20-946 1 HM400-1L
AISS FUNCTION DOES NOT WORK PROPERLY
Contents Of Trouble ● Even when the AISS switch is operated, the AISS function does not work normally.

1. AISS Low Switch

• Disconnect (AISS) connector from AISS switch and isolate switch.
At switch AISS, between (1) and (3), switch UP. (OL) open 2
A. AISS switch Resistance Ω At switch AISS, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 3
At switch AISS, between (1) or (3) and chassis ground. (OL) open 4

• Disconnect (AISS) connector from AISS switch and isolate connectors.
A. Open or high Voltage ✸ Between connector AISS, (1) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors AISS, (3) and DPC2A, (2) 0.0 to 1.0Ω 6
B. Short to chassis At connector AISS, between (3) and chassis ground. (OL) open 7
harness At connector AISS, between (1) and (3) (OL) open 8

Remark
HM400-1L 20-947 1
20-948 1 HM400-1L
RIGHT AND LEFT DIFFERENTIAL LOCK SWITCH DOES NOT WORK PROP-
ERLY
Contents Of Trouble ● Even when the differential switch is operated, the differential function does not work normally.

1. Differential Lock Switches

• Disconnect (DFL) connector from differential lock switch and isolate switch.
At switch DFL, between (1) and (3), switch UP. 0.0 to 1.0Ω 2
A. Lock switches Resistance Ω At switch DFL, between (1) and (3), switch in neutral. (OL) open 3
At switch DFL, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 4
• Disconnect (DFL) connector from differential lock switch and isolate connectors.
Voltage ✸ Between connector DFL, (1) and chassis ground. 20 to 30V 5
A. Open or high
Between connectors DFL, (2) and DPC3A, (2) 0.0 to 1.0Ω 6
Between connectors DFL, (3) and DPC3A, (3) 0.0 to 1.0Ω 7
At connector DFL, between (2) and chassis ground. (OL) open 8
B. Short to chassis At connector DFL, between (3) and chassis ground. (OL) open 9
harness At connector DFL, between (1) and (2) (OL) open 10
At connector DFL, between (1) and (2), (3) (OL) open 11

Remark
HM400-1L 20-949 1
20-950 1 HM400-1L
LEFT AND RIGHT DIFFERENTIAL PEDAL LOCK SYSTEM DOES NOT WORK
PROPERLY
Contents Of Trouble ● Differential pedal lock system does not work properly.

1. Differential Pedal Switch

• Disconnect (DFS) connector from lock switch and isolate switch.
At switch DFS, between (A) and (B), switch released. (OL) open 2
A. Pedal switch Resistance Ω At switch DFS, between (A) and (B), switch depressed. 0.0 to 1.0Ω 3
At switch DFS, between (A) or (B) and chassis ground. (OL) open 4
• Disconnect (DFS) connector from lock switch and isolate connectors.
A. Open or high Voltage ✸ Between connector DFS, (A) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors DFS, (B) and DPC3A, (1) 0.0 to 1.0Ω 6
B. Short to chassis
ground or within Resistance Ω At connector DFS, between (B) and chassis ground. (OL) open 7
harness

Remark
HM400-1L 20-951 1
20-952 1 HM400-1L
INNER AXLE DIFFERENTIAL LOCK SYSTEM DOES NOT WORK PROPERLY
Contents Of Trouble ● Inner axle lock system does not work properly.

1. Differential Pedal Switch

• Disconnect (DEF) connector from lock switch and isolate switch.
At switch DEF, between (1) and (3), switch UP. (OL) open 2
A. Lock switch Resistance Ω At switch DEF, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 3
At switch DEF, between (1) or (3) and chassis ground. (OL) open 4

• Disconnect (DEF) connector from lock switch and isolate connectors.
A. Open or high Voltage ✸ Between connector DEF, (1) and chassis ground. 20 to 30V 5
resistance Resistance Ω Between connectors DEF, (3) and DPC2A, (12) 0.0 to 1.0Ω 6
B. Short to chassis
ground or within Resistance Ω At connector DEF, between (3) and chassis ground. (OL) open 7
harness

Remark
HM400-1L 20-953 1
20-954 1 HM400-1L
EXHAUST BRAKE DOES NOT WORK PROPERLY
● Even when the exhaust brake switch is operated, the exhaust brake does not work normally, or
Contents Of Trouble the exhaust brake pilot lamp does not light up and go out normally (no failure code is dis-
played).

1. Exhaust Brake Switches

• Disconnect (EXH) connector from exhaust brake switch and isolate switch.
At switch EXH, between (1) and (2), switch UP. 0.0 to 1.0Ω 2
At switch EXH, between (1) and (2), switch in neutral. (OL) open 3
A. Brake switches Resistance Ω
At switch EXH, between (1) and (3), switch in neutral. (OL) open 4
At switch EXH, between (1) and (3), switch DOWN. 0.0 to 1.0Ω 5

• Disconnect (EXH) connector from exhaust brake switch and isolate connectors.
Voltage ✸ Between connector EXH, (1) and chassis ground. 20 to 30V 6

A. Open or high
Between connectors EXH, (2) and DPC2A, (11) 0.0 to 1.0Ω 7
Between connectors EXH, (3) and DPC2A, (3) 0.0 to 1.0Ω 8
At connector EXH, between (2) and chassis ground. (OL) open 9

B. Short to chassis At connector EXH, between (3) and chassis ground. (OL) open 10
harness At connector EXH, between (1) and (2) (OL) open 11
At connector EXH, between (1) and (2), (3) (OL) open 12

Remark
HM400-1L 20-955 1
20-956 1 HM400-1L
SEAT BELT CAUTION LAMP DOES NOT WORK PROPERLY
Contents Of Trouble ● Seat belt warning system does not work properly.

1. Seat Belt Switch

• Disconnect (SBS) connector from seat belt switch and isolate switch.
At switch SBS, between (1) and (2), belt connected. (OL) open 2
A. Belt switch Resistance Ω
At switch SBS, between (1) and (2), belt disconnected. 0.0 to 1.0Ω 3

• Disconnect (SBS) connector from seat belt switch and isolate connectors.
• Disconnect (DPC2B) connector from the monitor controller and install T-adapter on (DPC2B) wiring harness connector only.
A. Open or high Voltage ✸ Between connector SBS, (1) and chassis ground. 20 to 30V 4
resistance Resistance Ω Between connectors SBS, (2) and DPC2B, (11) 0.0 to 1.0Ω 5
B. Short to chassis
ground or within Resistance Ω At connector SBS, between (2) and chassis ground. (OL) open 6
harness

Remark
HM400-1L 20-957 1
20-958 1 HM400-1L
SIGNAL OR HAZARD LAMPS DO NOT WORK PROPERLY

Contents Of Trouble ● Even when turn signal lever and hazard lamps are switched to operate, no lamps light up.

Fuse Check ⎯ Check condition of fuse (BT2-24 and BT1-4) Fuse good? 1 Yes or No
1. Relay Check
• Disconnect listed relays and install a known good relays.
A. Relay test ⎯ Does system work normal when (R17) is replaced? ⎯ 2 Yes or No
B. Relay test ⎯ Does system work normal when (R16) is replaced? ⎯ 3 Yes or No
C. Flasher test ⎯ Does system work normal when flasher is replaced? ⎯ 4 Yes or No
2. Turn Switch Check

• Disconnect (CM) connector from turn switch and isolate switch.
At switch CM, between (6) and (7) switch in turn R. 0.0 to 1.0Ω 5
At switch CM, between (6) and (8) switch in turn L. 0.0 to 1.0Ω 6

• Disconnect (R16 and R17) connector from relay.
• Disconnect (CM) connector from turn switch.
• Disconnect (P04 and P03) connector from L.H. directional lamps.
• Disconnect (P30 and P29) connector from R.H. directional lamps.
• Disconnect (JO13) connector from winker lamps.
• Disconnect (DPC2A) connector from display panel and install T-adapter on (DPC2A) wiring harness connector only.
HM400-1L 20-959 1
Fuse Check ⎯ Check condition of fuse (BT2-24 and BT1-4) Fuse good? 1 Yes or No
1. Relay Check

Voltage
Between connectors R17, (3) and F1 (FLB) 0.0 to 1.0Ω 9
Between connectors R17, (2) and chassis ground. 0.0 to 1.0Ω 10
Between connectors R17, (1) and R16, (5) 0.0 to 1.0Ω 11
Between connectors R16, (4) and CM, (7) 0.0 to 1.0Ω 12

A. Open or high
Between connector R16, (4) and (P29) 0.0 to 1.0Ω 13
resistance
Resistance Ω Between connector R16, (4) and JO13, (1) 0.0 to 1.0Ω 14
Between connector R16, (2) and CM, (8) 0.0 to 1.0Ω 15
Between connector R16, (2) and (P04) 0.0 to 1.0Ω 16

Between connector R16, (4) and DPC2A, (7) 0.0 to 1.0Ω 17
Between connector R16, (2) and DPC2A, (16) 0.0 to 1.0Ω 18
Between connector R16, (1) and F1, (FLL) 0.0 to 1.0Ω 19
Between connector R16, (1) and CM, (6) 0.0 to 1.0Ω 20
B. Open or high At connector R16, between (1) and (3) 0.0 to 1.0Ω 22
Resistance Ω
resistance Between connectors R16, (2) and JO13, (4) 0.0 to 1.0Ω 23
At connector (P30) to chassis ground. 0.0 to 1.0Ω 24
At connector (P03) to chassis ground. 0.0 to 1.0Ω 25
Between connector (P04) and chassis ground. (OL) open 26

C. Short to Between connector (P29) and chassis ground. (OL) open 27
or within harness Between connector JO13, (1) and chassis ground. (OL) open 28
Between connector JO13, (4) and chassis ground. (OL) open 29
4. Hazard Switch Check

• Disconnect (HAZ) connector from hazard switch and isolate switch.
At switch HAZ, between (1) and (3) switch ON 0.0 to 1.0Ω 30

At switch HAZ, between (1) and (3) switch OFF (OL) open 31
Voltage ✸ Between connector HAZ, (1) and chassis ground. 20 to 30V 32

B. Switch circuit check Between connectors HAZ, (3) and R17, (1) 0.0 to 1.0Ω 33
Resistance Ω
Between connectors HAZ, (3) and R16, (5) 0.0 to 1.0Ω 34
20-960 1 HM400-1L
HM400-1L 20-961 1
HEAD AND TAIL LAMPS DO NOT WORK PROPERLY

Contents Of Trouble ● Head lamp system does not work properly.

Fuse Check ⎯ Check condition of fuses BT1, (6), (8), (10), (12) Fuses good? 1 Yes or No
1. Relay Check
A. Relay test ⎯ Does system work normal when (R30) is replaced? ⎯ 2 Yes or No
B. Relay test ⎯ Does system work normal when (R29) is replaced? ⎯ 3 Yes or No
Does system work normal when passing relay is
C. Passing relay test ⎯ ⎯ 4 Yes or No
replaced?
2. Light Switch Check

• Disconnect (CM) connector from light switch and isolate switch.
• Disconnect (LS) connector from dimmer switch and install a T-adapter between switch and connector.
At switch CM, between (3) and (1) switch ON. 0.0 to 1.0Ω 5
At switch CM, between (3) and (1) switch OFF. (OL) open 6
At switch CM, between (3) and (2) switch ON. 0.0 to 1.0Ω 7
Resistance Ω
At switch CM, between (3) and (2) switch OFF. (OL) open 8
A. Switch test
At switch CM, between (4) and (5) in HI beam. 0.0 to 1.0Ω 9
At switch CM, between (4) and (5) in LO beam. (OL) open 10
✸ At switch LS, between (2) and (3) turn switch left. 6 to 10V 11
Voltage
✸ At switch LS, between (2) and (3) turn switch right. 18 to 27V 12

• Disconnect (R30 and R29) connector from relay.
• Disconnect (CM) connector from light switch.
• Disconnect (LS) connector from dimmer switch.
• Disconnect (P01) connector from L.H. head lamps.
• Disconnect (P32) connector from R.H. directional lamps.
• Disconnect (P02), (P03), (P30), (P31) connector from running lamps.
• Disconnect (JO31) connector from stop lamps.
• Disconnect (DPC2A and DPC2B) connector from display panel and install T-adapter on (DPC2A and DPC2B) wiring harness connector only.
20-962 1 HM400-1L
Between connectors R29, (2), (4) and P01, (3), P32, (3) 0.0 to 1.0Ω 13
Between connectors R29, (2), (4) and DPC2A, (1) 0.0 to 1.0Ω 14
Between connectors R29, (2), (4) and R31, (8), (6) 0.0 to 1.0Ω 15
Between connectors R29, (1), (3) and CM, (1), (4) 0.0 to 1.0Ω 16
Between connectors R29, (5) and CM, (5) 0.0 to 1.0Ω 18
Between connectors R30, (6) and P01, (1), P32, (1) 0.0 to 1.0Ω 21
A. Open or high Between connectors R30, (3) and R31, (5), (7) 0.0 to 1.0Ω 22
Resistance Ω
resistance Between connectors R30, (2) and chassis ground. 0.0 to 1.0Ω 23
Between connectors R31, (1, 2, 3, 4) and CM, (3) 0.0 to 1.0Ω 24

Between connectors LS, (3) and chassis ground. 0.0 to 1.0Ω 26
Between connectors LS, (2) and DPC2B, (12) 0.0 to 1.0Ω 27

Between connectors LS, (1) and DPC2B, (5) 0.0 to 1.0Ω 28
Between connectors LS, (1) and CM, (2) 0.0 to 1.0Ω 29
Between connectors LS, (1) and P02 0.0 to 1.0Ω 30
Between connectors LS, (1) and P31 0.0 to 1.0Ω 31
Between connectors LS, (1) and JO13, (3), (6) 0.0 to 1.0Ω 31
Between connector CM, (2) and chassis ground. (OL) open 33

B. Short to Between connector CM, (3) and chassis ground. (OL) open 34
or within harness Between connector CM, (4) and chassis ground. (OL) open 35
Between connector CM, (5) and chassis ground. (OL) open 36
HM400-1L 20-963 1
20-964 1 HM400-1L
TROUBLESHOOTING FOR HYDRAULIC AND
MECHANICAL SYSTEM (H MODE)
(H-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1002
THE MACHINE DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1002
(H-2) AND (H-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1003
MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKEY) . . . . . . . . . . . . . . . . . . . 20-1003
LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING) . . . . . . . . . . . . . . . 20-1003
(H-4) AND (H-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1004
EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS . . . . . . . . . . . . . . . . . . 20-1004
TRANSMISSION WILL NOT UP SHIFT GEAR RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1004
(H-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1005
MACHINE LACKS POWER OR SPEED WHEN TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1005
(H-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1006
ABNORMAL OPERATION AT SOME SPEED RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1006
(H-6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1007
TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1007
(H-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1008
TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES . . . . . . . . . . . . . . 20-1008
(H-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1009
TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH) . . . . . . . . . . . . . . . . . . . 20-1009
(H-9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1010
TORQUE CONVERTER OIL PRESSURE LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1010
(H-10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1011
FRONT BRAKE IS INEFFECTIVE OR INNEFECTIVE ON ONE SIDE ONLY . . . . . . . . . . . . . . . . . 20-1011
(H-11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1012
CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE . . . . . . . . . . . . . . 20-1012
(H-12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1013
REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE ONLY . . . . . . . . . . . . . . . . . . . . . 20-1013
(H-13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014
STEERING EFFERT SEAMS HEAVY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014
(H-14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1015
STEERING SYSTEM DOES NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1015
(H-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1016
STEERING WHEEL VIBRATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1016
(H-16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1017
DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1017
(H-17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1018
DUMP OPERATIONS DO NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1018
(H-18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1019
EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1019
Remedy symbol Remedy

X Replace
∆ Repair
A Adjust
C Clean
HM400-1L 20-1001 1
TROUBLESHOOTING (H-1)
12
(H-1)
THE MACHINE DOES NOT MOVE

Cause
Ask The Operator About The Following a b c d e f g h i j k l m n
• Did the problem suddenly happen?
Defective speed clutch ECMV solenoid operation
Defective operation of speed clutch ECMV valve

Drop in pressure of power train main relief valve
• Yes: Internal seizures, damage
When this happened was there any noise?
Defective function of speed sensor

The power train pump is defective
Defective speed clutch piston seal

Breakage inside torque converter
Defective speed clutch shaft seal

• Yes: broken parts
Breakage inside transmission

Air in intake on suction side
Defective speed clutch

The PTO is defective
Clogging of strainer
Seized speed clutch

Inspection Before Diagnosis
• Is the oil level in the transmission correct?
• Is the torque converter, transmission input shaft broken?
• Use monitor to check speed sensor operation.
• Is drive shaft broken?
• Check all braking systems to se if they function normal?
• Is the retarder lever returned to RELEASE position?
• Are any codes displayed on monitor?
Remedy ∆ ∆
No. X C ∆ X X X X X X X X X
Diagnosis X X
1 Abnormal noise between power train pump and filter
2 The machine does not move in any specific gear range
3 The machine moves normal in certain speed ranges.
4 When trans. oil temp. rises, machine still does not move
5 Slow in every speed range
Slow at certain speed
6 Measure power train main
relief pressure. ranges
Pressure gauge readings
7 unstable
8 With pressure pickup port plug removed and engine

cranking no oil flows out of port.
9 Clutch pressure is abnormal
10 Power train main relief pressure is low
Clutch Used
Hi Lo 1st 2nd. 3rd. R

R2 ● ●
R1 ● ●
N
Speed Range
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
20-1002 1 HM400-1L
TROUBLESHOOTING (H-2) AND (H-3)
12
(H-2) AND (H-3)
MACHINE DOES NOT TRAVEL SMOOTHLY (MOVEMENT IS JERKEY)

Cause
Symptoms a b
• Engine governor hunts
Drop in set pressure of the power train main relief valve

• Lock-up pilot lamp flashes
Checks Before Troubleshooting

• Is the oil level in the transmission correct
Worn speed clutch seals

• Are any failure codes relating to the power train displayed.
No. Remedy See H-6

Diagnosis
1 Travel is not smooth
LOCK-UP CANNOT BE DISENGAGED (ENGINE STALLS WHEN STOPPING)

Cause
Symptoms a b c
• Engine governor hunts
• Lock-up pilot lamp flashes
Defective operation of lock-up ECMV solenoid
Defective operation of lock-up ECMV valve

Seized lock-up clutch

• Are any failure codes relating to the power train displayed.
Remedy C ∆
No. Diagnosis X X X
1 When lock-up clutch pressure is measured it does not go down to 0
2 When lock-up clutch pressure is measured it is at 0, but lock-up clutch is not disengaged
3 Operation of lock-up ECMV valve is normal
4 Operation of lock-up ECMV solenoid is normal
HM400-1L 20-1003 1
TROUBLESHOOTING (H-4) AND (H-5)
(H-4) AND (H-5)
EXCESSIVE SHOCK WHEN STARTING TO MOVE OR SHIFTING GEARS

Cause
Judgement Standard a b c
★ There is some shock during normal operations if possible compare with other machine of same model and make.
Defective operation of speed clutch ECMV pressure control valve spool
Defective operation of speed clutch ECMV flow detection valve spool

• It is clear that the shock is excessive
• Compared to other machines the shock is much greater
Defective operation of speed clutch ECMV solenoid

• Is any failure code displayed during operation?
Remedy C C
No. Diagnosis X X X
1 Excessive shock when starting movement or shifting gears
TRANSMISSION WILL NOT UP SHIFT GEAR RANGE

Checks Before Troubleshooting Cause
• Is any failure code displayed during operation? a b c d
• Probable cause (see table H-6)
Drop in set pressure of power train main relief valve
Clutch used
Defective operation of speed clutch ECMV
Hi Lo 1st. 2nd. 3rd. R
Slipping or damaged lock-up clutch
Defective speed clutch piston seal

R2 ● ●
R1 ● ●
N
Speed Range
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
No. Diagnosis ∆ ∆ X ∆X
Remedy X X C
1 Shifts up when traveling down hill
2 Does not shift up, regardless of road surface
20-1004 1 HM400-1L
12
(H-6)
MACHINE LACKS POWER OR SPEED WHEN TRAVELING

Causes
Checks Before Troubleshooting a b c d e f g h i j k
• Is there any oil leakage on the transmission or piping
Torque converter lock-up does not engage (carry out troubleshooting for H-6b)
• Are any of the brakes dragging
Defective operation of torque converter relief valve, or deteriorated spring
Excessive oil leakage inside torque converter (defective seal, loose plug)
• Is the retarder lever in the RELEASE position
• Are any failure codes displayed on monitor
Defective torque converter outlet piping, or oil cooler

Sucking air on suction side of power train pump
Defect inside torque converter (turbine failed)
Defective torque converter freewheel

Clogged power train pump strainer
Drop in performance of the engine
Defective power train pump

∆ ∆ ∆ ∆
No. Diagnosis ⎯
Remedy ∆ ∆
C X X X X X X X
1 Abnormal noise comes from between power train pump and filter
2 Torque converter stall speed is high
3 Torque converter stall speed is low
4 Low at every speed range (item 2 normal)
5 Measure power train main Oil pressure gage is unstable and fluctuates excessively
relief pressure
6 Pressure becomes low when lock-up is engaged
7 Hydraulic pressure at torque converter inlet port is low (Items 4 - 6 normal)
8 Hydraulic pressure at torque converter outlet port is low (Item 7 normal)
9 Pieces of iron and aluminum stuck to strainer and drain plug of transmission case
10 Hydraulic pressure at power train pump outlet port is low
11 When carrying out troubleshooting for item 10, if oil temperature rises, oil pressure drops
HM400-1L 20-1005 1
(H-6)
ABNORMAL OPERATION AT SOME SPEED RANGES

Causes
Checks Before Troubleshooting a b c d e f g h i j k l
• Are any braking system possibly dragging
• Are any failure codes relating to this system displayed
High clutch disk worn or seized, seal leaking or worn
Low clutch disk worn or seized, seal leaking or worn
2nd. clutch disk worn or seized, seal leaking or worn
3rd. clutch disk worn or seized, seal leaking or worn

1st. clutch disk worn or seized, seal leaking or worn
R. clutch disk worn or seized, seal leaking or worn
Defective operation of 2nd. clutch ECMV
Defective operation of 3rd. clutch ECMV

Defective operation of 1st. clutch ECMV
Defective operation of Lo clutch ECMV
Defective operation of HI clutch ECMV
Defective operation of R. clutch ECMV

Clutch used
R2 ● ●
R1 ● ●
N
Speed Range
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
No. Diagnosis X X X X X X X X X X X X
Remedy
1 F2, F4, and F6 are abnormal, but other speed ranges are normal
Same as item 1, but condition returns to normal when ECMV for HI clutch is replaced
2 with ECMV for R clutch.
3 F1, F3, and F4 are abnormal, but other speed ranges are normal
Same as item 3, but condition returns to normal when ECMV for Lo clutch is replaced
4
with ECMV for R clutch.
5 F1, F2, and R1 are abnormal, but other speed ranges are normal
6 Same as item 5, but condition returns to normal when ECMV for 1st. clutch is
replaced with ECMV for R clutch.
7 F3, F4, and R2 are abnormal, but other speed ranges are normal
Same as item 7, but condition returns to normal when ECMV for 2nd. clutch is
8 replaced with ECMV for R clutch.
9 F5 and F6 are abnormal, but other speed ranges are normal.
Same as item 11, but condition returns to normal when ECMV for 3rd. clutch is
10
replaced with ECMV for R clutch.
11 R1 and R2 are abnormal, but other speed ranges are normal
12 Same as item 11, but condition returns to normal when ECMV for R. clutch is replaced
with ECMV for Hi clutch.
20-1006 1 HM400-1L
12
(H-6)
TORQUE CONVERTER LOCK-UP DOES NOT ENGAGE

Causes
Ask The Operator About The Following a b c d e f g
• Did the problem suddenly happen?
• Yes: Internal seizure, damage
When this happened was there any noise?
• Yes: broken parts
Drop in set pressure of the power train main relief valve
Defective operation of lock-up ECMV solenoid spool

Defective operation of lock-up ECMV valve spool

• Is there any external leakage from piping or valve assembly?
• Are any failure codes relating to this system displayed?
Defective lock-up ECMV solenoid
Worn lock-up clutch piston seals
Cracked lock-up clutch case

Worn lock-up clutch disc
Diagnosis ∆ ∆ ∆ ∆
No. X X X
Remedy X X X X
2 With item 1 normal, lock-up pressure is low or none
3 With item 2 abnormal, no open or short circuit is found in lock-up ECMV solenoid
4 With item 2 abnormal, no open or short circuit is found in lock-up ECMV solenoid
5 With item 1 - 4 normal, lock-up oil pressure is low
6 With item 1 - 4 normal, lock-up oil pressure is normal
7 When oil pressure is measured, main relief pressure and lock-up clutch pressure are both low
8 Lock-up takes time to engage
HM400-1L 20-1007 1
(H-7)
TIME LAG EXCESSIVE DURING MOVEMENT OR SPEED RANGE CHANGES

Causes
Checks Before Troubleshooting a b c d e f g h i j k l m n o p q r
• Is there any external leakage from piping or valve
assembly?
• Is operation of control valve normal?
Air is being sucked in at suction side of power train pump
2nd. clutch disc worn or defective or worn seals

3rd. clutch disc worn or defective or worn seals
1st. clutch disc worn or defective or worn seals
Lo clutch disc worn or defective or worn seals
Hi clutch disc worn or defective or worn seals
R. clutch disc worn or defective or worn seals

Incorrect oil causing tightness of speed clutch
Defective operation of 2nd. clutch ECMV

Defective operation of 3rd. clutch ECMV
Defective operation of 1st. clutch ECMV
Defective operation of Lo clutch ECMV
Defective operation of Hi clutch ECMV
Defective operation of R. clutch ECMV

Defective seals on high speed clutch
Clutch used Defective power train pump

R2 ● ●
R1 ● ●
N
Speed Range
F1 ● ●
F2 ● ●
F3 ● ●
F4 ● ●
F5 ● ●
F6 ● ●
No. Diagnosis C ∆
∆
∆ X ∆ X X X X X X X X X X X X
Remedy X X
1 Abnormal noise comes from around power train pump
2 There is a time lag in any speed range
3 There is a time lag when shifting to F2, F4, F6
4 There is a time lag when shifting to F1, F3, F4
5 There is a time lag when shifting to F1, F1, R1
6 There is a time lag when shifting to F3, F4, R2
7 There is a time lag when shifting to F5, F6,
8 There is a time lag when shifting to R1, R2
9 Clutch pressure is low when placed in any speed range
10 Torque converter oil temperature goes above operating range
20-1008 1 HM400-1L
(H-8)
TORQUE CONVERTER OIL TEMPERATURE IS OUT OF RANGE (HIGH)

Causes
Ask The Operator About The Following a b c d e
• Does the oil temperature go up when the torque converter is stalled and go down when not stalled?
• Yes = Normal (but if stalling is frequent, selection of speed range is incorrect)
Oil leakage inside torque converter (defective seals or internal failure)

Sucking air in the suction side of the port train pump
Defective operation of torque converter relief valve

Clogged power train filter

Diagnosis C ∆ X X ∆
No. X X
Remedy
1 Power train pump makes abnormal noises when oil temperature is low
2 Low idle and high idle speeds are extremely low
3 Torque converter outlet oil pressure is low
4 Torque converter inlet pressure is low
5 Clutch pressure is low
6 Excessive leakage inside torque converter
★ If the results of all troubleshooting items are normal, this is the probable cause.
HM400-1L 20-1009 1
(H-9)
TORQUE CONVERTER OIL PRESSURE LOW

Causes
Checks Before Troubleshooting a b c d e
Air is being sucked into the inlet side of the power train pump
Drop in set pressure of torque converter relief valve
Excessive leakage inside torque converter

Defective power train pump

Diagnosis C C ∆ ∆ ∆
No. X X X
Remedy
1 Abnormal noise comes from power train
3 Torque converter inlet pressure is low
4 Torque converter inlet pressure is low (lock-up pressure and clutch pressure are normal)
5 When torque converter relief valve is adjusted, inlet pressure becomes high
20-1010 1 HM400-1L
12
(H-10)
FRONT BRAKE IS INEFFECTIVE OR INNEFECTIVE ON ONE SIDE ONLY

Causes
Checks Before Troubleshooting a b c d e f g h i j k l m n o
• Is the brake pedal play correct?
• Is there ant oil leakage from the brake piping?
• Is the tire inflation and tread ware good?
Drop in accumulator gas pressure (gas leakage, defective seal)

• Are any failure codes relating to the system being displayed?
Air is being sucked into the suction side of the PPC pump
Defective rear brake pressure reducing valve

Defective operation of wheel brake piston
Defective PPC pump drive system (PTO)
Defective accumulator charge valve
Defective wheel brake piston seal

Defective brake valve (front)
Breakage inside wheel brake

Defective slack adjuster
Defective retarder lever

Worn wheel brake disc
Defective PPC pump
Air in brake circuit
Inner axle oil level

∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆
No. Diagnosis X ∆ X X X X X X X X X X X ∆ X
Remedy
1 Brake has no effect only when brake pedal is depressed
2 When brake pedal is depressed it feels light
3 When brake pedal is depressed it feels heavy
4 When retarder lever is pulled retarder has no effect (not used in E-SPEC)
5 Extreme amount of effort needed to obtain specific braking effect
6 When brakes are applied, abnormal noise is heard from brakes
7 Hydraulic and steering do not work
8 Abnormal noise is heard from around PTO
9 Abnormal noise is heard around transmission oil pan or PPC pump
When oil is drained from axle case, large amounts of metal particles are
10
found
11 Accumulator charge pressure is low
12 Brake immediately losses power after engine is stopped
13 There is a time lag before brake starts to take effect
14 Brake oil pressure is low
15 Brake disc wear is excessive
16 Air is found when bleeding the braking system
HM400-1L 20-1011 1
(H-11)
CENTER BRAKING SYSTEM IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE

Causes
Checks Before Troubleshooting a b c d e f g h i j k l m n o

Defective rear brake pressure reducing valve

Defective brake valve (center rear)

Defective retarder lever

Defective PPC pump

∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆
No. Diagnosis X ∆ X X X X X X X X X X X ∆ X
Remedy
4 When retarder lever is pulled retarder has no effect (not used in E-SPEC)
When oil is drained from axle case, large amounts of metal particles are
10
found
20-1012 1 HM400-1L
12
(H-12)
REAR BRAKE IS INEFFECTIVE OR EFFECTIVE ON ONE SIDE ONLY

Causes
Checks Before Troubleshooting a b c d e f g h i j k l m


Defective brake valve (center, rear)


Defective PPC pump

∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆
No. Diagnosis X ∆ X X X X X X X X X ∆ X
Remedy
9 When oil is drained from axle case, large amounts of metal particles are found
HM400-1L 20-1013 1
12
(H-13)
STEERING EFFERT SEAMS HEAVY

Causes
Checks Before Troubleshooting a b c d e f g h i
• Is the oil level in the hydraulic tank correct?
• Is there any oil leakage between the pump flow amplifier valve and the steering valve?
• Does the steering wheel have the correct amount of play?
Air is being sucked in at the suction end of the hydraulic steering pump
• Is the differential lock systems off when turning the machine?
Defective operation of flow amplifier valve spool or stuck spool

Drop in pressure of flow amplifier valve, relief valve or bad oil
Defective hydraulic and steering pump drive system (PTO)
Damaged suction tube in hydraulic and steering pump

Clogged hydraulic and steering pump strainer
Defective hydraulic and steering pump
Defective steering cylinder

Defective steering valve
∆ ∆
No. Diagnosis ∆ C ∆ ∆ X XA ∆ X X
Remedy
1 Dump cylinder also does not work
2 When pressure pick-up port plug is removed and engine is cranked, no oil comes out of port
3 Dump operations are normal
4 Steering oil pressure is low at end of cylinder stroke (item 3 normal)
5 Item 4 is abnormal, relief noise is heard from relief valve
6 Abnormal noise comes from between hydraulic, steering pump - filter
7 Steering wheel works when engine is at low idle
When steering wheel is turned fully to the left, and hose on opposite side is disconnected large quantities of
8
oil flows out the disconnected hose port
9 Hydraulic and steering pump discharge quantity low
10 Excessive play in steering wheel
20-1014 1 HM400-1L
12
(H-14)
STEERING SYSTEM DOES NOT OPERATE

Causes
Checks Before Troubleshooting a b c d e f g h i
• Is there any oil leakage between the pump flow amplifier valve and the steering valve?
• Does the steering wheel have the correct amount of play?
Air is being sucked in at the suction end of the hydraulic steering pump
• Is the brake (service or retarder) operating?

Damaged suction tube in hydraulic and steering pump

Defective steering cylinder

Defective steering valve
∆ ∆
No. Diagnosis ∆ C ∆ ∆ X XA ∆ X X
Remedy
1 Dump cylinder also does not work
2 When pressure pick-up port plug is removed and engine is cranked, no oil comes out of port
3 Dump operations are normal
4 Steering oil pressure is low at end of cylinder stroke (item 3 normal)
5 Item 4 is abnormal, relief noise is heard from relief valve
6 Abnormal noise comes from between hydraulic, steering pump - filter
7 Steering wheel works when engine is at low idle
When steering wheel is turned fully to the left, and hose on opposite side is disconnected large quantities of
8
oil flows out the disconnected hose port
9 Hydraulic and steering pump discharge quantity low
10 Excessive play in steering wheel
HM400-1L 20-1015 1
12
(H-15)
STEERING WHEEL VIBRATES

Causes
Checks Before Troubleshooting a b
• Is any failure code relating to this system displayed
Air in hydraulic oil (oil is created)

Air inside steering cylinder
Diagnosis ∆
No. A X
Remedy
1 Steering even vibrated
20-1016 1 HM400-1L
12
(H-16)
DUMP BODY LIFTING SPEED IS SLOW OR LACKS POWER

Causes
Checks Before Troubleshooting a b c d e f g h i j k l
• Is there any external oil leakage between the pump - dump valve - dump cylinder?
Drip in set pressure of dump valve relief valve or incorrect or contaminated oil
Air is being sucked in at the suction side of the hydraulic and steering pump
• Is the single valve of dump lever within normal range
• Are there any failure codes relating to this system displayed?

Defective operation of check valve or dump valve

Broken hydraulic and steering pump suction tube
Drop in dump EPC valve or defective operation


Defective dump EPC pump
Defective dump cylinder

Defective dump lever
∆ ∆
No. Diagnosis C ∆ ∆ X X XA ∆ X X X ∆ X
Remedy
1 Steering also does not work normally
2 Steering works normal
3 Steering relief pressure and dump relief pressure is low
4 Item 3, abnormal relief noise is heard from the relief valve
5 Dump relief pressure is too high with engine at high idle speed
6 Dump relief pressure is low
7 Item 6, abnormal noise is heard from the relief valve
8 Dump body does not rise smoothly (movement irregular)
9 Hydraulic and steering pump discharge amount is low
10 Items 1 - 9 are normal but dump body lift speed is slow
11 Abnormal noise is heard between hydraulic steering pump and filter
12 Dump EPC valve oil pressure is low
HM400-1L 20-1017 1
12
(H-17)
DUMP OPERATIONS DO NOT WORK

Causes
Checks Before Troubleshooting a b c d e f g h i j k l m
Drop in set pressure of flow amplifier valve, relief valve or incorrect or contaminated oil
• Is signal valve on dump body within normal range?
Drop in set pressure of dump valve relief valve or incorrect or contaminated oil
• Are any failure codes displayed relating to this system
• Is the battery charge circuit caution lamp lit-up
Air is being sucked in at the suction end if the hydraulic steering pump
(If the alternator signal R is not within range the dump controller will not operate)

Defective operation of check valve of dump valve

Broken suction tube on hydraulic steering pump
Drop in dump EPC valve or defective operation


Defective dump EPC pump
Defective dump cylinder

Defective dump lever
Diagnosis ∆ ∆ ∆ C X X ∆ ∆ X X
A
∆ X
No. XA
Remedy X
1 When pressure pick-up port plug is removed and engine is cranked, no oil comes out of
port
2 Steering also does not work normal
3 Steering works normal
4 Item 2 is abnormal, steering relief pressure and dump relief is low
5 Item 4 is abnormal, abnormal noises are heard from around the relief valve
6 Dump relief pressure is low
7 Item 6 is abnormal, abnormal noises are heard from around the relief valve
8 Dump relief pressure is low at engine high idle
9 Normal when engine is at low idle
10 Hydraulic and steering pump discharge amount is low
When dump body is raised, and hose at LOWER end of dump cylinder id removed, a
11
massive amount of oil flows out.
20-1018 1 HM400-1L
12
(H-18)
EXCESSIVE HYDRAULIC DRIFT IN DUMP BODY

Causes
Checks Before Troubleshooting a b
• Is any failure code relating to this system displayed

Slipping or damaged lock-up clutch
Diagnosis ∆ ∆
No.
Remedy X X
Excessive amounts of oil flows out
1 Raise dump body and disconnect hose at head (LOWER) end of dump cylinder
Little or no oil flows out
HM400-1L 20-1019 1
12
MEMORANDUM
20-1020 HM400-1L
30 DISASSEMBLY AND ASSEMBLY
HOW TO USE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

PRECAUTIONS WHEN CARRYING OUT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
SKETCHES OF SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
FUEL SUPPLY PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
FUEL SUPPLY PUMP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
ENGINE ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
ENGINE ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
CYLINDER HEAD ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
REMOVAL AND INSTALLATION OF NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
RADIATOR ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
RADIATOR ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
OUTPUT SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
OUTPUT SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
OUTPUT SHAFT DISASSEMBLY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
ASSEMBLY OF OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
TRANSMISSION AND FRONT DIFFERENTIAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
TRANSMISSION AND FRONT DIFFERENTIAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
DISCONNECTION OF FRONT DIFFERENTIAL AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
COUPLING OF FRONT DIFFERENTIAL AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-73
DISASSEMBLY OF TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
ASSEMBLY OF TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
DISASSEMBLY OF TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
ASSEMBLY OF TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114
DISASSEMBLY OF FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-150
ASSEMBLY OF FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
REMOVAL OF CENTER DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
INSTALLATION OF CENTER DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-177
DISASSEMBLY OF CENTER DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179
ASSEMBLY OF CENTER DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-187
REAR DIFFERENTIAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
REAR DIFFERENTIAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201
DISASSEMBLY OF REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
ASSEMBLY OF REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
REMOVAL OF FRONT FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
INSTALLATION OF FRONT FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-220
ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228
REMOVAL OF CENTER FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
INSTALLATION OF CENTER FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-241
ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-248
REMOVAL OF REAR FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-256
INSTALLATION OF REAR FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-257
DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-258
ASSEMBLY OF REAR FINAL DRIVE AND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-265
HM400-1L 30-1
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
REMOVAL OF CENTER AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-272
INSTALLATION OF CENTER AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-275
REMOVAL OF REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-277
INSTALLATION OF REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-280
REMOVAL OF FRONT SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-281
INSTALLATION OF FRONT SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-282
REMOVAL OF REAR SUSPENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-283
REMOVAL OF EQUALIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-285
INSTALLATION OF EQUALIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-287
REMOVAL OF FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
INSTALLATION OF FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-288
REMOVAL AND INSTALLATION OF REAR WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-289
REMOVAL OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-291
INSTALLATION OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-297
DISASSEMBLY OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-299
ASSEMBLY OF HITCH FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-301
STANDARD INTEGRAL ORBIT-ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-304
DISASSEMBLY OF STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-306
ASSEMBLY OF STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-310
REMOVAL OF FLOW AMPLIFIER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-316
INSTALLATION OF FLOW AMPLIFIER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-317
REMOVAL OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-318
INSTALLATION OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-319
DISASSEMBLY OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-320
ASSEMBLY OF HOIST VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-321
DISASSEMBLY OF STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-323
ASSEMBLY OF STEERING CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-325
DISASSEMBLY OF HOIST CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-328
ASSEMBLY OF HOIST CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-330
REMOVAL OF BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-334
INSTALLATION OF BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-336
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-337
30-2 HM400-1L
DISASSEMBLY AND ASSEMBLY HOW TO USE MANUAL
12
HOW TO USE MANUAL
1. When removing or installing unit assemblies
A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal opera-
tion; the order of work for the installation operation is not given.
B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation
(COMPONENT) REMOVAL Title of operation
WARNING! Safety precautions to observe when performing an operation
1. XXX Text of or name of procedural step
A. Text of procedural step if 1 was procedural name
★ Technique or important point
Reference to a special technique during assembly or installation (note that

this symbol is right-aligned).
(COMPONENT) INSTALLATION Title of operation
• Installation is the reverse of removal. Overall directive
Special technique during assembly or installation (note that this symbol is

left-aligned).
(Component/assembly) Specification
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the
operation.
3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see
the SPECIAL TOOLS LIST given in this manual.
HM400-1L 30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
12
PRECAUTIONS WHEN CARRYING OUT OPERATION
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

● If the coolant contains antifreeze dispose of it correctly.
● After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
● When draining oil, prepare a container of adequate size to catch the oil.
● Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
● To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the con-
nectors. Do not pull the wires.
● Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
● Check the number of thickness of the shims, and keep in a safe place.
● When raising components, be sure to use lifting equipment of ample strength.
● When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
● Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Hoses and tubes using sleeve nuts

Nominal
Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
B. Face seal type hoses and tubes

Nominal
Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
C. 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
30-4 HM400-1L
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
D. If the part is not under hydraulic pressure, the following corks
can be used.
Nominal Dimensions (mm)
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
2.Precautions when carrying out installation work

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

● If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate
the water through the system. Then check the water level again.
● If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
● If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
● Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
HM400-1L 30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79 T- - cannot be supplied (they are items to be locally manufactured).
★ Necessity: : Cannot be substituted, should always be installed (used).
:Extremely useful if available, can be substituted with commercially available part.
★ New/remodel: N: Tools with new part numbers, newly developed for this model.
R:Tools with upgraded part numbers, remodeled from items already available for other modes.
★ Blank: Tools already available for other modes, used without any modification.
★ Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
Neces- New/
Component Symbol Part No. Part Name Q’ty Sketch Nature of work, remarks
sity remodel
Wrench Removal, installation of cyl-

1 790-331-1110 1
inder head
795-521-1110 Push tool 1
790-101-5221 Grip 1
For front
01010-51225 Bolt 1
01050-31640 Bolt 3 Press fitting of
2 crankshaft oil
795-931-1210 Sleeve 1 seal
795-931-1220 Sleeve 1
For rear
01050-31625 Bolt 3
Disassembly, assem-
A 01050-31645 Bolt 3
bly of engine
795-471-1320 Plate 1
01017-32020 Bolt 1 Removal of Fuel supply

3
01010-81095 Bolt 2 pump
01643-31032 Washer 2
792-220-1110 Centering tool 2 Carrying out shaft of engine

4 assembly and transmission
01050-61225 Bolt 8 assembly
Removing and installing noz-
5 795T-471-1550 Wrench 1
zle tips
790-201-2210 Plate 1
790-201-2740 Spacer 1
791-600-1120 Bolt 1
790-101-2540 Washer 1
1 Press fitting of shaft bearing
01580-01613 Nut 1
Disassembly, assem- 01643-31645 Washer 2

B
bly of output shaft 790-101-2102 Puller (30 tons) 1
790-101-1102 Hydraulic pump 1
790-101-5401 Push tool kit 1
790-101-5431 Plate 1
2 Press fitting of cage oil seal
790-101-5421 Grip 1
01010-51240 Bolt 1
30-6 HM400-1L
Neces- New/ Ske-

Component Symbol Part No. Part Name Q’ty Nature of work, remarks
sity remodel tch
790-501-5000 Unit repair stand 1 AC100V
Disassembly,
Unit repair stand AC110V,
790-501-5200 1 assembly of
1 220V
torque converter
790-901-2110 Bracket 1 assembly
792T-413-1110 Plate 1 N
792-420-1110 Centering tool 1
792-420-1120 • Flange 2 Centering of engine and torque
2
792-413-1120 • Collar 1 converter
01050-31230 • Bolt 8
Wrench Removal, installation of pump
Disassembly, assem- 3 792-103-5110 1
bearing locknut
bly of torque con- C
verter Nut wrench Removal, installation of PTO
4 790-102-1871 1
gear bearing set nut
5 790-201-2730 Spacer 1 Press fitting of pump bearing
Push tool Press fitting of stator shaft bear-
6 793T-623-1170 1 N
ing
7 792T-413-1120 Push tool 1 N Press fitting of gear bearing
8 792T-413-1130 Push tool 1 N Press fitting of coupling cover
790-101-5401 Push tool kit 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-201-2750 Spacer 1
1 Press fitting of shaft bearing
790-201-2850 Spacer 1
790-101-5401 Push tool kit 1
790-101-5461 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
3 792T-415-1310 Push tool 1 N Press fitting of coupling cover
Oil leak tester kit Check of operation of clutch pis-
4 799-301-1500 1
ton
792T-415-1320 Block 2 N Disassembly of 2nd and 3rd
5
Disassembly, assem- 01010-81050 Bolt 2 clutch assembly
D
bly of transmission 790-101-2501 Push puller 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
790-101-2540 • Washer 1
790-101-2560 • Nut 2 Pulling out of FH & 1st clutch
6
790-101-2570 • Plate 4 bearing inner case
790-101-2630 • Leg 2
790-101-2660 • Adapter 2
791-112-1180 • Nut 1
790-201-1320 • Spacer 1
HM400-1L 30-7
Neces- New/ Ske-

sity remodel tch
790-201-2850 Spacer 1
Press fitting of bevel pinion
1 790-201-2740 Spacer 1
bearing (For R/F differential)
790-201-2750 Spacer 1
790-101-5401 Push tool kit 1
790-101-5481 • Plate 1 Press fitting of oil seal to cage
2
790-101-5421 • Grip 1 (For front differential)
01010-51240 • Bolt 1
For rear dif-
790-201-2770 Spacer 1
ferential
Press fitting of
3 For front dif- output shaft seal
792T-423-1130 Push tool kit 1 N ferential, R/F
differential
790-201-2740 Spacer 1 Press fitting of shaft bearing
4 792T-423-1110 Push tool 1 N (For front differential, R/F dif-
792T-423-1120 Push tool 1 N ferential)
5 792T-423-1130 Push tool 1 N Press fitting of cage input seal

792-103-0901 Wrench 1
Adjustment of preload on bear-
6 792-222-1110 Adapter 2
ing
795-525-1000 Micrometer 1
796-751-1500 Wrench assembly 1 Measurement of turning torque
7
Disassembly, assem- 795-630-1803 Torque wrench 1 of side gear
H
bly of axle Push tool Press fitting of pin (for differen-
8 792T-422-1250 1 N
tial assembly)
790-501-5000 Unit repair stand 1 AC100V
Disassembly,
790-501-5200 Unit repair stand 1 AC110, 220V assembly of dif-
9
790-901-2110 Bracket 1 ferential assem-
793-310-2141 Plate 1 R bly
792T-422-1260 Push tool 1 N

790-101-5421 Grip 1
01010-51240 Bolt 1
790-101-5401 Push tool kit 1 Press fitting of differential lock
10
gauge input seal
790-101-5471 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
792T-423-1140 Push tool 1 N
790-101-5421 Grip 1
01010-51240 Bolt 1
790-101-5401 Push tool kit 1 Press fitting of differential (R/F)
11
gauge input seal
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
30-8 HM400-1L
Neces- New/ Ske-

sity remodel tch
792T-422-1210 Fixture 3 N For rear
Removal, instal-
792T-427-1110 Fixture 3 N For front
1 lation of brake
01010-61435 Bolt 3 assembly
01010-62440 Bolt 3
792T-422-1220 Plate 1 N
2 790-101-5421 Grip 1 Press fitting of oil seal
Disassembly, assem-
01010-51240 Bolt 1
bly of final drive and J
brake 3 792T-422-1230 Push tool 1 N Press fitting of bearing to hub
4 792T-422-1240 Push tool 1 N Press fitting of bearing to tube
792-520-2110 Installer 1 For large
792-530-1600 Push tool 1 diameter Fitting of float-
5
Installer For small ing seal
790-434-1620 1
diameter
6 793-520-1805 Brake tester 1 Check for brake oil leakage
Disassembly, assem- 792-620-1001 Tire remover 1 Removal of tire from wheel
R 1
bly of wheel 790-101-1102 Hydraulic pump 1 assembly
792T-446-1110 Push tool 1 N
Press fitting of bearing to hitch
1 792T-446-1120 Push tool 1 N
frame
792T-446-1150 Push tool 1 N
790-101-5401 Push tool kit 1
790-101-5461 • Plate 1
Disassembly, assem- 2 Press fitting of oil seal to frame
790-101-5421 • Grip 1
bly of hitch frame
01010-51240 • Bolt 1
792T-446-1130 Plate 1 N
792T-446-1140 Plate 1 N Press fitting of oil seal to cage
3
790-101-5421 Grip 1 and frame
01010-51240 Bolt 1
790-201-1702 Push tool kit 1
Q
790-201-1881 • Push tool 1
4 Press fitting of roll bushing
790-201-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit 1
790-201-1690 • Plate 1
Disassembly, assem- 5 Press fitting of dust seal
bly of suspension 790-101-5021 • Grip 1
01010-50816 • Bolt 1
Suspension tool
792-610-1000 1
assembly
6 792-610-1100 • Pump assembly 1 Filling with oil and nitrogen gas
• Charging tool
792-610-1200 1
assembly
HM400-1L 30-9
Neces- New/ Ske-

sity remodel tch
Disassembly, assem- 790-452-1100 Seal installer set 1 Disassembly, assembly of steer-

T 1
bly of steering valve 790-452-1200 Pilot ring tool 1 ing valve
Cylinder repair
790-502-1003 1 Disassembly, assembly of
1 stand
hydraulic cylinder
790-101-1102 Hydraulic pump 1
Removal, installation of cylinder
2 790-102-3802 Wrench assembly 1
head
Socket (Width Removal, installation of nylon
3 790-102-1480 1
across flats: 80 mm) nut (For steering cylinder)
790-720-1000 Expander 1
796-720-1670 Ring 1 Steering, No.
4 07281-01279 Clamp 1 2 hoist Installation of
796-7201680 Ring 1 For No. 1 piston ring
07281-01289 Clamp 1 hoist cylinder
790-201-1702 Push tool kit 1
790-101-5021 • Grip 1
Disassembly, assem-
bly of hydraulic cylin- U 01010-50816 • Bolt 1
der For steering Press fitting of
5 790-201-1811 Push tool 1
cylinder roll bushing
For No. 1
790-201-1881 Push tool 1
hoist cylinder
For No. 2
790-201-1841 Push tool 1
hoist cylinder
790-201-1500 Push tool kit 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
For steering Press fitting of
6 790-201-1620 • Plate 1
cylinder dust seal
For No. 1
790-201-1690 • Plate 1
hoist cylinder
For No. 2
790-201-1650 • Plate 1
hoist cylinder
795-471-1700 Remover 1
Disassembly, assem- 795-471-1520 • Block 1 Removal of fuel

V 1
bly of engine 795-471-1530 • Bolt 1 supply pump
01435-01085 • Bolt 2
30-10 HM400-1L
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A5 Wrench
HM400-1L 30-11
C1 Plate
C6 Push tool
30-12 HM400-1L
C7 Push tool
C8 Push tool
HM400-1L 30-13
D3 Push tool
D5 Block
30-14 HM400-1L
H3, H5 Push tool
H4 Push tool
HM400-1L 30-15
H4 Push tool
H8 Push tool
30-16 HM400-1L
H9 Plate
H10 Push tool
HM400-1L 30-17
H4 Push tool
J1 Fixture
30-18 HM400-1L
J1 Fixture
J2 Push tool
HM400-1L 30-19
J3 Push tool
J4 Push tool
30-20 HM400-1L
Q1 Push tool
Q1 Push tool
HM400-1L 30-21
Q1 Push tool
Q3 Push tool
30-22 HM400-1L
Q3 Push tool
HM400-1L 30-23
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP REMOVAL
FUEL SUPPLY PUMP REMOVAL

1. Align 1.6 TOP stamp line a of damper (2) with pointer (1).
2. Remove breather tube (3).
3. Remove plugs (4) (2 places, at the upper and lower part), then
check that the stamp line is aligned with the fuel supply pump drive
gear and forcing tap hole.
4. Remove cover (5). Remove gear mounting nut and washer (6) and
(7) with care not to drop them in the engine.
5. Set gear forcing jig A3.

★ Tool bolt A3 must be mounted at the gear forcing tap hole (2
places).
6. Remove fuel hose (9), then remove fuel tube (10), fuel supply tube
(11), oil tube (12), and overflow tube (13).
★ Mask the joints and joint portions of piping to keep dust and
debris out.
7. Remove harness connectors (14) and (15).

★ Mask the connector parts to keep dust and debris out.
30-24 HM400-1L
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP INSTALLATION
8. Loosen bolts (16) and nuts (17) of the bracket and fuel supply
mounting bolts (18) (4 places on the front and rear sides).
9. Clockwise rotate tool bolt (center bolt) A3 to pull out the fuel sup-
ply pump drive gear.
★ Key (19) is inside, be careful not to drop it.
10. Remove bolts (16) and nuts (17) loosened at step 9, then remove
fuel supply pump (20).
FUEL SUPPLY PUMP INSTALLATION

● Install in the reverse order of removal.
● General bolts and nuts conform to KES04.123.1.
● Unspecified joint bolts conform to D07206-XXXXX.
Plug: 14.7 - 19.6 N•m
● Installing the fuel supply pump drive gear

Nut: 176.5 - 196.1 N•m
● Fuel filter side
Joint bolt: 24.5 - 34.3 N•m
● Fuel supply pump tube

★ Place the cap with its slit toward the cylinder block side.
● Supply pump side
Tube: 39.2 - 49.0 N•m
● Common rail side

Tube: 49.0 - 58.8 N•m
● Air clamp
Mounting bolt upper side: 4.9 ± 1.0 N•m
Mounting bolt lower side: 9.8 ± 1.0 N•m
★ Other clamps conform to KES
HM400-1L 30-25
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY REMOVAL
ENGINE ASSEMBLY REMOVAL
WARNING! Disconnect the cable from the negative

(–) terminal of the battery.
1. Bleed the air conditioner gas.
2. Drain the coolant.
3. Engine undercover
Remove the engine undercover.
4. Tilting up operator's cab

Bring the hood down forward (and fix it) and tilt up operator's cab
(1) and support it with the safety bar.
WARNING! Check that the operator's cab is sup-

ported securely with the safety bar.
5. Engine top cover and cooling water reservoir tank

Remove engine top cover (2) and cooling water reservoir tank (3).
★ Disconnect the radiator (cooling) water level connector (CN-
B01), too.
6. Pipes and hoses
A. Remove cover (34).
B. Disconnect coolant (engine overflow) hose (5), radiator over-

flow hose (6), radiator inlet hose (7), and make-up hose (8),
then remove aftercooler tube and hose (9) and (10).
C. Loosen the clamp of air cleaner tube (11) and shift it to the
right of the vehicle body.
30-26 HM400-1L
7. Fan guard
Remove fan guard (12).
8. Fan
Remove fan (13).
★ Bring the fan down toward the radiator.
9. Air conditioner compressor

Remove air conditioner compressor (14).
★ The air conditioner compressor must be removed so that the
tool (socket joint) can be inserted to remove the front left
mounting bolt of the engine.
10. Water pump inlet hose

Remove water pump inlet hose (15).
11. Fuel hoses

Disconnect fuel supply hose (16) and return hose (17).
HM400-1L 30-27
12. Exhaust pipe
Remove exhaust pipe (18).
13. Starting motor wiring harnesses and engine ground wire

Disconnect starting motor wiring harnesses (20) and (21) and
engine ground wire (22).
★ The starting motor wiring harness (21) is installed from the
right side of the engine through the front side to the battery and
secured with four clamps. Remove all of those four clamps so
that they will not interfere with the right front mounting
bracket when the engine assembly is raised.
14. Alternator wiring harnesses, heater hoses, fuel spill tubes, and
exhaust brake linkage
Disconnect alternator wiring harnesses (22) (three places, four
pieces), heater hoses (23) and (24), fuel spill tube (25) (two pieces),
and exhaust brake linkage (34). Remove radiator lower tube and
hose (35).
30-28 HM400-1L
15. Engine centralized connector and heater relay connector
Remove cover (26) and disconnect engine centralized connector
(27) (CN-EG4, EG5) and heater relay connector (28).
16. Hydraulic hoses and drive shaft between engine and transmission
A. Disconnect hydraulic hoses (29) (three pieces) from the left

front side of the vehicle body.
B. Remove guard bracket (30) from the output shaft cover and
disconnect drive shaft (31) between the engine and transmis-
sion from the engine.
17. Engine mounting bolts

Remove engine mounting bolts (32) (four pieces).
HM400-1L 30-29
18. Engine assembly
Lift off engine assembly (33).
Engine assembly: 1,700 kg (3,748 lbs)
30-30 HM400-1L
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY INSTALLATION
ENGINE ASSEMBLY INSTALLATION

• Carry out installation in the reverse order of removal.
Charge the air conditioner with refrigerant (R134a).
• When installing the drive shaft, check that the key way of the spider cap is matched to that of the mating yoke and tighten
the bolts.
Drive shaft mounting bolts between engine and transmission:

Adhesive (LT-2)
Mounting bolts of drive shaft between engine and transmis-

sion: 98 - 123 N•m
Target: 113 N•m
Engine mounting bolt: 662 - 829 N•m

Target: 113 N•m
★ When dismantling the engine assembly, transmission and torque converter assembly or drive shafts, center the engine
and transmission in the left and right direction in the following manner, using tool A4.
A. Install tool A4 to the coupling on the engine side and the coupling on the torque converter side.
B. Put scale [1] to the left and right sides of tool A4.
C. Measure the clearance between scale [1] and tool A4 on the left
side "a" and on the right side "b".
★ Check that the maximum clearance remains below 3 mm
both on the left and right sides. (If both clearances are not
in parallel, check that the clearance remains less than 3
mm even at the widest point)
★ If the clearance exceeds 3 mm, make adjustment by shift-
ing the position of torque converter and transmission
assembly mount.
★ When installing the drive shaft, check that the keyway of
spider cap fully engage with that of the corresponding
yoke, and then tighten the mounting bolt.
Mounting bolt: Liquid adhesive compound (LT-2)
HM400-1L 30-31
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY INSTALLATION
Mounting bolts of drive shaft between engine and transmis-

sion: 98 - 123 N•m
Target: 113 N•m
★ When measuring dimension "a" between the flywheel housing and the coupling tip, while drive shaft (43)
between the engine and transmission is in place, and if this dimension "a" falls out of the value shown below,
make adjustment by shifting the position of engine assembly mount or transmission and front differential assem-
bly mount so that the dimension falls within the specified value.
Dimension "a" between flywheel housing and coupling tip: 210.2 -30 mm
Refilling with coolant
Add coolant to the coolant filler of the radiator. Run the engine to circulate the coolant through the system. Then, check the
coolant level in the reservoir tank again.
Refilling with oil
Add engine oil (specified oil: EO30-CD) to the specified level.
30-32 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY REMOVAL
CYLINDER HEAD ASSEMBLY REMOVAL
WARNING! Disconnect the cable from the negative (-)

terminal of the battery.
1. Tilt up operator's cab (1) and support it with the safety bar.

2. Remove engine top cover (2) and coolant reservoir tank (3).
★ Disconnect the radiator coolant level connector (CN-B01), too.
3. Remove aftercooler hose (4) and air cleaner hose (5).
HM400-1L 30-33
4. Turbocharger and exhaust manifold assembly
A. Remove heat insulation plate (6) and muffler pipe (7).
B. Remove exhaust brake linkage (8).
C. Disconnect turbocharger lubrication tube (9).
D. Sling turbocharger and exhaust manifold assembly (10) temporarily and

remove the mounting bolts, then remove the assembly.
Turbocharger and exhaust manifold assembly:

30 kg (66 lbs)
5. Air intake manifold
A. Remove corrosion resistor (11), fuel filter (12), and oil filter
(13).
★ Make match marks on the hoses and refer to them when connecting
the hose again
30-34 HM400-1L
B. Remove the wiring harness clamp, each fuel injector connec-
tor, and fuel supply pump connector (14), then move wiring
harness (15).
★ Insert flat-head screwdriver B in the shouldered part (part "a")

of the fuel injector part (part "a") and move it in the direction
X, pressing the stopper of (16a), and fuel injector connector
(16) is disconnected.
(16b): On fuel injector wiring harness side.
C. Disconnect air intake pressure sensor connector (17).
D. Remove spill tube (18).
E. Remove bracket (19).
F. Seeing air intake connector (20) from the front side of the
engine, remove the mounting bolt at the left lower part.
HM400-1L 30-35
G. Sling exhaust manifold assembly (21) temporarily and remove
the mounting bolt, then remove the assembly.
6. Ribbon heater
Remove ribbon heater wiring harness (22) to remove each ribbon heater
(23).
7. High-pressure fuel pipe
B. Remove clamp (25) and gate-type frame (26).
C. Remove splash guard rubber boot from the high-pressure pipe

fitting part.
D. Remove each clamp (27) and each high-pressure pipe (28).
8. Aeration tube and water tube

Remove aeration tube (29) and water tube (30) on the exhaust side
of the cylinder head.
9. Head cover
Remove head cover (31).
30-36 HM400-1L
10. Rocker arm
A. Remove three mounting bolts and rocker arm (32).

★ Loosen lock nut (34) and loosen adjustment screw (35) by two
to three turns so that an excessive force will not be applied to
push rod (33) when the rocker arm is installed again.
11. Fuel injector assembly
A. Remove two nuts (37) of the upper solenoid valve of fuel injec-
tor (36) and pull out spring clamp (38).
B. Remove the bolt of clamp (39), one mounting bolt (42) of

holder (41) of connector (with O-ring) (40) and holder (41),
then push in connector (40) to remove it.
C. Loosen the bolt of holder (44) of fuel injector (36), then

remove fuel injector (36).
D. Insert a small L-bar under connection (45) of fuel injector (36)

carefully.
★ Never hold the solenoid valve on the top of the injector with
priers, etc.
★ Precautions for removing only injector to replace only injector
or only nozzle tip.
Before starting the above work to remove the injector, loosen
the bolts mounting the injector onto the clamp intake manifold
near the injectors of high-pressure pipe clamps No.1 - No.6.
Remove the sleeve of the high-pressure pipe on the injector
side and pull out the injector, taking care that its tip will not
touch the concave part of the injector.
HM400-1L 30-37
12. Push rod
Remove push rod (46).
13. Cylinder head assembly, Cross head
A. Remove cross head (47).
B. Remove mounting bolts (48) and cylinder head assembly (49).
C. Remove each cylinder head gasket.
30-38 HM400-1L
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD INSTALLATION
CYLINDER HEAD INSTALLATION

● Carry out installation in the reverse order of removal.
★ Tighten the bolts in the order shown in the following figure.
Turbocharger mounting bolt: 44.1 - 49 N•m
Turbocharger and exhaust manifold assembly:

58.8 - 73.5 N•m
Spill tube: 8 - 9.8 N•m
1. Fit the gaskets to both sides of ribbon heater (23) and install them to
air intake manifold assembly.
2. Install wiring harness (22) to ribbon heater (23) and assemble them
with the air intake manifold
3. Install the air intake manifold to the cylinder head.

★ Tighten the bolts in the order shown in the following figure.
Air intake manifold assembly: 59 - 74 N•m
HM400-1L 30-39
A. Tighten all the bolts of the five high-pressure pipe clamps by
hand, then tighten them permanently. Then, secure the clamp
stays permanently.
B. Tighten all the bolts of the stays and upper and lower clamps of
high-pressure pipe clamps (25), (52), (53) by hand.
C. Tighten the bolts of the upper and lower clamps permanently

(to bend the rubber before securing the stay permanently).
Clamp bolt: 9.8 ± 1.0 N•m
★ At this time, secure the clamps in the order of (25), (52)

and (53). [If the clamps are secured in this order, excessive
forces are not applied to the mounting parts of the supply
pump (Stress concentration on the mounting parts of the
supply pump is prevented).]
D. Secure the stays in the order of (25), (52), and (53).
E. Install gate frame (26) temporarily. Secure clamp (on the back
side of the gate frame) permanently first, then secure gate
frame (26) permanently with special bolts (4).
Clamp bolt: 9.8 ± 1.0 N•m
★ There are 16 rubber caps. All of them have respective slits, the
directions of which are important.
F. Caps at common rail outlet (50) with their slits toward the cyl-
inder block.
30-40 HM400-1L
G. Fit the six rubber caps at fuel injector inlet sleeve (51) with
their slits down.
★ Secure the rubber caps with metal clips
★ When installing the high-pressure pipe, check it for visible lon-

gitudinal slit "b", pit "c", or level difference (wear) in part "d"
(End of the taper seal: Part of 2 mm from the end) which is felt
with a nail in the taper seal part of the connecting section (Part
"a": 2 mm from the end). If any of those defects can cause fuel
leakage, replace the high-pressure pipe.
● Screw sleeve nut (54) by two turns with the hand into the
threads of the fuel injector, then tighten it with a spanner.
Note1)If sleeve nut (54) does not catch the threads, press its
end with another small spanner, etc. and turn its hexagonal part
with the proper spanner.
Sleeve nut: 22.5 - 24.5 N•m
Note2)After finishing the work make sure that O-ring is not

projected from the sleeve.
Water tube: 9.8 - 12.7 N•m
Head cover: 14.7 - 34.3 N•m
★ Check that the ball of the adjustment screw is fitted to the

socket of the push rod.
★ Adjust the valve clearance. For details, see TESTING AND
ADJUSTING, Adjusting valve clearance.
HM400-1L 30-41
Rocker arm assembly mounting bolt: 93 - 103 N•m
Locknut: 53 - 64.7 N•m
★ When installing the high-pressure pipe, check it for visible lon-

gitudinal slit "b", pit "c", or level difference (wear) in part "d"
(End of the taper seal: Part of 2 mm from the end) Which is felt
with a nail in the taper seal part of the connecting section (Part
"a": 2 mm from the end). If any of those defects can cause fuel
leakage, replace the high-pressure pipe.
★ Make sure that the inside of the injector sleeve is free from dirt.
H. Fit the gasket and O-ring to the fuel injector and apply engine
oil SAE No. 30 to them.
I. Insert holder (41) in fuel injector (36), then insert them simul-
taneously with the injector connection directed to the hole for
the fuel high-pressure pipe.
J. Fit the ball washer and holder (41) to bolt (42), then tighten
them temporarily. Insert high-pressure pipe sleeve (55) in the
hole for the fuel high-pressure pipe and secure it temporarily,
matching it to injection (56). Secure holder (41) with bolt (42)
permanently.
★ Apply engine oil to the spherical surface of the ball washer
(to fit the ball washer).
Holder mounting bolt: 58.8 - 73.5 N•m
★ After securing the holder, remove the high-pressure pipe sleeve

and install the other injectors in order according to the above
procedure.
30-42 HM400-1L
★ It is difficult to insert the connector from inside with the O-ring
fitted to it.
K. Remove O-ring (58) from wiring harness connector (57). Take

wiring harness connector (57) out of the connector hole and
install O-ring (58) and apply engine oil SAE No. 30 to them.
Install connector holder (41) and push it in and secure it with
mounting bolt (59).
L. Install wring harness terminal (61) to injector terminal (60) and

tighten two nuts (62). Insert wiring harness holder clamp (63)
in the injector connection and secure wiring harness clamp (64)
with bolt (65).
Terminal nut: 1.8 - 2.2 N•m
★ Eliminate the slack of the wiring harness and press it

against the body of the injector.
HM400-1L 30-43
★ Adjust the cross head according to the following procedure.
M. Loosen the locknut and return the adjustment screw.
N. Holding the top of the cross head (47) lightly, tighten the
adjustment screw.
O. After the adjustment screw touches the valve stem, tighten it

further by 20°.
P. Tighten the locknut

.
Locknut: 53 - 64.7 N•m
4. Check that the cylinder head mounting face and inside of the cylin-
der are free of foreign matter, then set cylinder head gasket.
★ When fitting the gasket, check that the grommets are fitted cor-
rectly.
5. Before tightening the cylinder head mounting bolts, check the fol-
lowing item.
★ If a bolt is longer than the following using limit or has been
tightened five times (having five punch marks denoting the
number of tightening times) or more, replace it.
A. Measure stem length "a" of every bolt and make sure that it is
less than the using limit.
B. Using limit length of bolt

Short bolt: 170.8 mm
Long bolt: 205.8 mm
30-44 HM400-1L
6. Install cylinder head assembly and tighten mounting bolts.
Mounting bolt: Lubricant containing molybdenum disulfide

(LM-P)
★ A special socket to tighten the head bolts is necessary.
Mounting bolt:
1st time: 137 - 157 N•m
2nd time: 284 - 294 N•m
3rd time: When using tool A1 (the angle tightening
wrench), tighten the bolts by 90° in the order of (1) -
(6).
★ After tightening bolts (1) - (6), tighten bolt (7) to 66.6 ±7.4
Nm.
● When not using tool A1, make marks on the bolts and
head with paint, then tighten the bolts by 90° +3 in the
order of (1) - (6).
★ After tightening bolts (1) - (6), tighten bolt (7) to 66.6 ±7.4
Nm.
HM400-1L 30-45
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF NOZZLE TIP
REMOVAL AND INSTALLATION OF

NOZZLE TIP
★ [EPA regulations]
For countries subject to EPA regulations, the entire nozzle assembly
of the common rail engine shall be replaced if any of its compo-
nents needs to be replaced. For other countries, the following pro-
cedure may be applied for replacing the nozzle tip.
★ The 125 Engine Series are used as examples in all of the following
photos. However. the procedures for removing and installing the
nozzle chip shown in these photos are applicable to the other
engines as well.
REMOVAL
1. Fix tool A5 in vice B.

★ Do not pinch the injector directly in the vice.
2. Set injector assembly (3) on tool A5.
3. Loosen rerating nut (4) with 19 mm deep socket D.
30-46 HM400-1L
4. Remove rerating nut (4) from injector assembly (3).
5. Lift nozzle assembly (5) perpendicularly upward to remove it.

★ Do not remove tip guide (6). (Disassembling the portion after
the tip guide is not allowed.)
★ Be careful not to get the assembly dirty.
INSTALLATION
1. Fix tool A5 in vice B.

★ Do not pinch the injector directly in the vice.
2. Set injector assembly (1) on tool A5.
3. Completely clean the lower body and screw sections of retaining

nut (2) with parts cleaner, and apply air blow.
HM400-1L 30-47
4. Mount new nozzle assembly (3) so that the assembly fits the knock
pin of tip guide (4).
★ Be careful not to drop the tip.
5. Mount nozzle assembly (3) and manually tighten retaining nut (2).
6. Set 19-mm deep socket C in the torque wrench, then tighten the
retaining nut by following the steps below.
★ Apply rust prevention oil on the nozzle body.
A. Tighten with torque of 88.3 Nm.
B. Attach identification mark (6) to retaining nut (2) and lower

body (5).
C. Tighten at an angle of 45º (angle tightening)
30-48 HM400-1L
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY REMOVAL
RADIATOR ASSEMBLY REMOVAL

1. Drain the cooling water.
2. Radiator undercover
Remove the radiator undercover.


4. Pipes and hoses above radiator
B. Disconnect cooling water (engine overflow) hose (5), radiator

overflow hose (6), radiator inlet hose (7), and make-up hose
(8), then remove aftercooler tube and hose (9) and (10).
C. Loosen the clamp of air cleaner tube (11) and shift it to the
right of the vehicle body.
5. Pipes and hoses under radiator
A. Disconnect heater hose (14) and remove radiator lower tube

and hose (15).
HM400-1L 30-49
B. Disconnect power train and brake circuit cooling hoses (16)
and (17) and steering and hoist circuit cooling hoses (18) and
(19).
6. Fan guard
Remove fan guard (12).
7. Fan
Remove fan (13).
★ Bring the fan down toward the radiator.
30-50 HM400-1L
8. Air conditioner condenser and front covers
A. Remove air conditioner condenser (20) and shift it forward and

fix it (by binding with strings).
B. Remove front covers (21) (two pieces).
9. Stays
Remove stays (22) from both sides.
★ Measure the installed dimensions.
10. Radiator assembly
A. Sling radiator assembly (23) (including the fan) temporarily

and remove mounting bolts (24).
HM400-1L 30-51
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY INSTALLATION
B. Lift off radiator assembly (23) (including the fan).
Radiator and fan assemblies: 340 kg (750 lbs)
RADIATOR ASSEMBLY INSTALLA-

TION
● Install radiator in the reverse order of removal.
Install the radiator assembly so that clearance "a" between it and

front guard will be 13 - 15 mm.
Add coolant to the coolant filler of the radiator. Run the engine to circu-
late the coolant through the system. Then, check the coolant level in the
reservoir tank again.
30-52 HM400-1L
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT REMOVAL
OUTPUT SHAFT REMOVAL



2. Vertical member
Remove vertical member (2).
Vertical member: 45 kg (99 lbs)
3. Hoist and steering pump
A. Disconnect suction pipes (3) and (4) and hoses (5), (6), and (7).
B. Lift off hoist and steering pump assembly (9).
Hoist and steering pump assemblies: 45 kg (99 lbs)
HM400-1L 30-53
4. Brake cooling and differential lock (machine with differential lock
differential) pump
A. Disconnect suction pipe and hose (10) and (11) and discharge
hoses (12) and (13).
B. Lift off brake cooling and differential lock pump assembly

(14).
Brake cooling and differential lock pump: 30 kg (66

lbs)
5. Drive shaft between engine and transmission
A. Remove guard bracket (15) from the output shaft cover and
sion.
Drive shaft between engine and transmission:

55 kg (121 lbs)
30-54 HM400-1L
6. Coupling and oil seal cage
Remove coupling (17) and oil seal cage (18).
7. Output shaft cover

Remove snap ring (19), then remove cover (20) by using forcing
screw B and guide bolt C.
8. Output shaft
Using forcing screw B and guide bolt C remove output shaft (21).
9. Bearing
Remove bearing (22).
HM400-1L 30-55
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT INSTALLATION
OUTPUT SHAFT INSTALLATION

● When installing the drive shaft, check that the key way of the spider
cap is matched to that of the mating yoke and tighten the bolts.
★ Using tool C2, align the engine and torque converter with each
other.

Adhesive (LT-2)
Drive shaft mounting bolts between engine and transmis-

sion: 98 - 123 N•m
● For details of filling with ENS grease, see DISASSEMBLY,

ASSEMBLY OF OUTPUT SHAFT ASSEMBLY.
Spline: ENS grease
★ 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.)
ENS grease Part No.: 427-12-11871 (2kg can)
Bearing cover mounting bolt: Thread tightener (LT-2)
Bearing cover mounting bolt: 98 - 123 N•m
Raise the cover and set to the output shaft, use tool B1 to press fit the
inner bearing, then install cover (20).
Output shaft mounting bolt: Thread tightener (LT-2)
Bearing cover mounting bolt: 98 - 123 N•m
Bearing: Coat whole surface of bearing inside diameter and shaft out-
side diameter with ENS grease.
30-56 HM400-1L
DISASSEMBLY AND ASSEMBLY OUTPUT SHAFT DISASSEMBLY DIAGRAM
OUTPUT SHAFT DISASSEMBLY DIAGRAM
1. Oil cage assembly

Remove oil seal (1) from cage (2).
2. Cover assembly
Remove bearing (3) from cover (4).
3. Damper assembly (5)
A. To keep the balance when reassembling, mark the set positions of flange (6), body assembly (7), and outer body (9)
before disassembling.
B. Remove body assembly (7) and rubber (8) from outer body (9).
C. Remove bearing (10) from flywheel.
HM400-1L 30-57
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF OUTPUT SHAFT
ASSEMBLY OF OUTPUT SHAFT

1. Using push tool, press fit bearing (10) in flywheel.
Flywheel hole portion, inside of bearing: ENS grease
2. Assembly of damper assembly.
A. Coat mating surface of outer body (9) and one side of flange
(6) with adhesive, then assemble.
Flange mating surface: Adhesive (LG-4)
Mounting bolt: Thread tightener (LT-2)
Mounting bolt: 66.2 ± 7.4 N•m
B. Install body assembly (7).
C. Assemble rubber (8).

★ Before assembling, coat with grease.
Outer body, body assembly, rubber: Grease (L2-L1)
D. Install flange (6).

Flange mating surface: Adhesive (LG-4)
★ Align the marking position of the outer body, inner body, and
flange, then assemble.
30-58 HM400-1L
3. Install damper assembly (5) to flywheel.
Body assembly shaft spline: ENS grease
4. Press fit bearing (3) in cover (4).

Bearing: ENS grease
5. Install cover assembly to flywheel
Cover assembly: 35 kg (77 lbs)
6. Assemble oil seal (1) in (2).

Oil seal: ENS grease
7. Install cage assembly to cover assembly.
● Procedure for filling with ENS grease
A. ENS grease Part No.: 427-12-11871
B. Places to fill with grease, amount of ENS grease (total amount:

approximately 225g), and places to coat with grease.
HM400-1L 30-59
a: 60% pack (30g) g: Fill between grease lip and dust lip
b: Coat all surfaces of bearing inner dia. and shaft outer h: 50% pack (30g)
dia. i: Full pack (20g)
c: Fill three points in 20 mm width on circumference at j: Coat all spline.
labyrinth. k: Full pack (25g)
d: 60% pack (30g) l: Full pack (30g)
e: B-B m: 90% pack (25g)
f: Full pack (35g)
30-60 HM400-1L
DISASSEMBLY AND ASSEMBLYTRANSMISSION AND FRONT DIFFERENTIAL REMOVAL
TRANSMISSION AND FRONT DIFFERENTIAL REMOVAL

1. Discharge the air conditioner refrigerant.
2. Drain the cooling water.
3. Drain the hydraulic oil and transmission oil.
4. Lower the transmission undercover. (Do not disconnect it from the

hinge.)
5. Tilt up operator's cab


6. Joint connectors between cab and vehicle body

Disconnect joint connectors (2) (ten places) between the cab and
vehicle body.
★ Before disconnecting, make match marks.
7. Brake hoses (on brake valve side)

Disconnect brake hoses (3) (five pieces) (on the brake valve side).
★ Before removing the clamps, check the positions of the hoses.
8. Steering hoses
Disconnect steering hoses (5) (five pieces).
9. Heater hoses
Disconnect heater hoses (4) (five pieces).
HM400-1L 30-61
10. Operator's cab lift cylinder
Remove the connecting pin on the cab side and disconnect opera-
tor's cab lift cylinder (62)
11. Operator's cab assembly

Pull mounting pins (6) on both sides of the rear section outward and
lift off operator's cab assembly (7).
★ Loosen the muffler cover mounting bolts and shift the muffler
cover so that the mounting pin will not interfere with it.
★ Do not remove the pins, just move them outward.
Operator’s cab assembly: 1300 kg (2,866 lbs)
12. Transmission rear brake hoses
A. Disconnect right rear brake hoses (8) (Upper side: four pieces,
Lower side: two pieces)
30-62 HM400-1L
B. Disconnect right rear brake hoses (9) and (10).
C. Disconnect left rear brake hoses (11) and (12)
(Section above transmission)
13. Vertical member

Remove vertical member (13).
Vertical member: 45 kg (99 lbs)
14. Frame and hose assembly

Remove frame and hose assembly (14).
HM400-1L 30-63
15. Centralized connectors between vehicle body and engine
Remove top cover (15) and disconnect centralized connectors (16)
and (17) between the vehicle body and engine.
16. Steering pipes and hoses

Disconnect steering hoses (18) - (22) and remove orifice (23).
17. Centralized oil pressure pickup hoses

Disconnect centralized oil pressure pickup hoses (24) (five pieces).
18. Intermediate connectors, torque converter oil pressure sensor con-

nector, exhaust brake hoses, and brake oil drain hose
A. Disconnect intermediate connectors (CN-DT1) (25), (CN-

DT2) (26), and (CN-TD3) (27).
30-64 HM400-1L
B. Disconnect torque converter oil pressure sensor connector (28),
exhaust brake hoses (29) (two pieces), and brake oil drain hose
(30).
(Section above front of transmission)
19. Hoist and steering pump
A. Disconnect suction pipes (31) and (32) and hoses (33), (34),
and (35).
B. Lift off hoist and steering pump assembly (37).
Hoist and steering pump assembly: 45 kg (99 lbs)
20. Brake cooling and differential lock (machine with differential lock
differential) pump
A. Disconnect suction pipe and hose (38) and (39) and discharge
hoses (40) and (41).
HM400-1L 30-65
B. Lift off brake cooling and differential lock pump assembly
(42).
Brake cooling and differential lock pump assembly:

30 kg (66 lbs)
21. Drive shaft between engine and transmission
A. Remove guard bracket (43) from the output shaft cover and
sion.
Drive shaft between engine and transmission:

55 kg (121 lbs)
30-66 HM400-1L
(Section under front of transmission)
22. Torque converter and transmission charge pump hoses, differential

lock hoses, brake hoses, and brake cooling hoses
A. Disconnect torque converter and transmission charge pump

hoses (45) and (46), differential lock hoses (47) - (49), and
brake cooling hose (50).
B. Disconnect brake hoses (51) and (52).
C. Disconnect brake cooling hoses (53) and (54).
(Section under left rear of transmission)
23. Subtank (Tank for brake) pipe

Disconnect subtank (tank for the brake) pipe (55).
★ Remove the pipe coupling.
HM400-1L 30-67
24. Transmission rear mount grease tube
Disconnect rear mount grease tube (56) from the rear mount.
25. Drive shaft between transmission and hitch frame

Disconnect the guard and drive shaft (57) between the transmission
and hitch frame from the transmission.
26. Drive shafts on both sides (between front differential and front final
drive)
Disconnect drive shafts (58) on both sides (between front differen-
tial and front final drive) from the front differential.
30-68 HM400-1L
27. Transmission and front differential assembly
Remove mounting bolts (59) (Front side: four pieces) and (60)
(Rear side: eight pieces) and lift off transmission and front differen-
tial assembly (61).
Transmission and front differential assembly:

2,100 kg (4,630 lbs)
HM400-1L 30-69
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND FRONT DIFFERENTIAL INSTAL-
TRANSMISSION AND FRONT DIFFERENTIAL INSTALLATION

● Add refrigerant (R134a).
● Standard clearance "a" for operator's cab mounting pin: 0.2 mm (on
each side)
★ Using tool C2, align the engine and torque converter with each
other.

Adhesive (LT-2)
Drive shaft mounting bolts between engine and trans-

mission: 98 - 123 N•m
Target: 113 N•m
Drive shaft mounting bolts between transmission and hitch

frame: Adhesive (LT-2)
Drive shaft mounting bolts between transmission and hitch

frame: 157 - 198 N•m
Target: 177 N•m
30-70 HM400-1L
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND FRONT DIFFERENTIAL INSTAL-
Drive shafts mounting bolts on both sides (between front dif-

ferential and front final drive): Adhesive (LT-2)
Drive shaft mounting bolts on both sides (between front

differential and front final drive: 98 - 123 N•m
● Standard shim thickness "b" for front mounting bolt: 1 mm

● Standard shim thickness "c" for rear mounting bolt: 2 mm.
Front mounting bolt: 1,150 - 1,440 N•m
Rear mounting bolt: 171.5 - 214.5 N•m
WARNING! After installing, bleed air from the brake

circuit. For details, see TESTING AND
ADJUSTING, Bleeding air from brake cir-
cuit.

• Add coolant to the coolant filler of the radiator. Run the engine to
circulate the coolant through the system. Then, check the coolant
level in the reservoir tank again.
Refilling with oil

• Add engine oil (specified oil) to the specified level.
• Add transmission oil (specified oil) to the specified level.
• Supply the front differential case with specified oil to the specified level.
HM400-1L 30-71
DISASSEMBLY AND ASSEMBLY DISCONNECTION OF FRONT DIFFERENTIAL AND
DISCONNECTION OF FRONT DIFFER-

ENTIAL AND TRANSMISSION
1. Piping
Remove hose and piping (1).
2. Torque converter and transmission assembly and brake pump

Remove the torque converter and transmission assembly and brake
pump (2).
3. Front output shaft speed sensor of transmission

Remove cover (3) and speed sensor (4).
30-72 HM400-1L
DISASSEMBLY AND ASSEMBLYCOUPLING OF FRONT DIFFERENTIAL AND TRANSMIS-
4. Front differential assembly
Lift off front differential assembly (5).
Front differential assembly: 450 kg (992 lbs)
COUPLING OF FRONT DIFFERENTIAL

AND TRANSMISSION
Adjust the speed sensor. For details, see TESTING AND ADJUSTING.
Front differential mounting bolt: Adhesive (LT-2)
Front differential mounting bolt: 490 - 608 N•m
HM400-1L 30-73
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TORQUE CONVERTER
DISASSEMBLY OF TORQUE CON-

VERTER
1. P.T.O. assembly
Using eyebolt B, tighten forcing screw C to remove P.T.O. assem-
bly 1.
2. Torque converter assembly
A. Loosen all mounting bolts (2) and remove all but three of them.
B. Place torque converter housing (3) on block D with the pump

side down.
C. Remove mounting bolts (2) left in step A above. Using eyebolt

E, remove torque converter assembly (4).
3. Turbine and clutch assembly
A. Set torque converter assembly (4) to tool C1.
30-74 HM400-1L
B. Remove mounting bolts (5) on the pump side.
C. Using eyebolt F, remove turbine and clutch assembly (6). For

further disassembly, see "Disassembly of turbine and clutch
assembly."
4. Stator assembly
Lift up and remove stator assembly (7).
★ For further disassembly, see "Disassembly of stator assembly."
5. Pump assembly
A. Using tool C3, remove nut (8).
HM400-1L 30-75
B. Using puller G, remove inner race (9) and pump assembly (10)
C. Remove the mounting bolts, retainer (11), and guide (12).
D. Using push tool H, remove bearing (13) from guide (12).
6. Stator shaft
A. Remove the plug. Using a bar, remove inner race (15) from sta-
tor shaft (14).
★ When installing the plug again, do not apply adhesive (LT-2).
B. Remove bushing (16).
C. Remove seal ring (17).
30-76 HM400-1L
7. Disassembly of turbine and clutch assembly
A. Using forcing screw I, remove input shaft (18).
B. Using puller J, remove bearing (19).
C. Remove snap ring (20) and plate (21).
D. Using forcing screw 1), remove turbine (22)
E. Remove the mounting bolts and lift off housing assembly (23).
F. Remove piston (24) and seal ring (25) from the housing assem-
bly.
HM400-1L 30-77
G. Using push tool 1!, remove bearing (26) from the housing.
H. Remove seal ring (27).
I. Remove pin (28).
J. Remove disc (30) from case (29).
8. Disassembly of stator assembly
A. Remove the mounting bolts and stator (31).
B. Remove bushings (33) and (34) from race (32).
C. Remove race (35) and free wheel (36) from race (32).
30-78 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TORQUE CONVERTER
ASSEMBLY OF TORQUE CONVERTER

1. Assembly of stator assembly
A. Install free wheel (36) and race (35) to race (32).

★ Install the free wheel with the arrow of the gauge end on
the input side.
★ Apply engine oil EO30-CD or EO10-CD to the sliding
surfaces of the races.
B. Install bushings (34) and (33) to race (32).

★ Install the bushings by expansion fit.
surfaces.
★ Put in the ball without fail.
C. Install stator (31) to race (32).
Mounting bolt: Adhesive (LT-2)
Mounting bolt: 58.8 - 73.5 N•m
★ Check the rotating direction of the stator

View from input side
Clockwise: Free
Counterclockwise: Locked
2. Assembly of turbine clutch assembly
A. Set turbine (22) and case (29) to push tool B.

★ Use a block to prevent case (29) from touching turbine
(22).
HM400-1L 30-79
B. Install disc (30).
surfaces.
C. Install pin (28).

★ Install pin (28) to the housing by expansion fit.
D. Install the seal rings (27) and (25) to piston (24) and housing
(23).
Seal ring: Grease (G2-L1)
E. Install the piston to housing assembly (23).

surfaces of the piston.
★ When installing the piston take care that the seal rings will
not be caught.
F. Sling housing assembly (23) and install it to case (29).
G. Using push tool C, press fit bearing (26).
30-80 HM400-1L
H. Install plate (21) and snap ring (20).
I. Using the push tool, press fit bearing (19) to input shaft (18).
J. Install input shaft (18) to the housing.
3. Stator shaft
● The following is the assembly procedure for the torque con-
verter.
A. Set stator shaft (14) to tool C1 and turn it over.
B. Using the push tool, install bushing (16) by expansion fit.

★ Press fit the bushing with the chamfered end directed to
the stator shaft.
C. Install the seal ring (17).
Seal ring: Grease (G2-L1)
D. Using the push tool, press fit inner race (15).
HM400-1L 30-81
4. Pump assembly
A. Using push tool 1$, press fit bearing (13) to guide (12).
B. Set guide (12) and retainer (11) and tighten the mounting bolts.
C. Set pump assembly (10) and inner race (9).

★ Drop 10 cc of engine oil EO30-CD or EO10-CD onto the
bearing and rotate the bearing ten turns.
D. Using push tool 1%, press fit inner race (9).
30-82 HM400-1L
E. Using tool C3, tighten nut (8).
Nut: Adhesive (LT-2)
Nut: 441.3 - 490.3 N•m
5. Stator assembly
Install stator assembly (7).
● For further assembly, see "Assembly of stator."
6. Turbine and clutch assembly

Using eyebolt F, set turbine and clutch assembly (6) to the pump
and tighten the mounting bolts.

Using eyebolt E, set torque converter assembly (4) to torque con-
verter housing (3) and tighten the mounting bolts.
HM400-1L 30-83
8. P.T.O. assembly
Fit the O-ring and install P.T.O. assembly (1), using eyebolt B.
30-84 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF TRANSMISSION
DISASSEMBLY OF TRANSMISSION
1. Piping
Remove hoses and piping (1).
2. Wiring harness assembly

Remove wiring harness assembly (2).
3. Torque converter and transmission assembly and charge pump (3)

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).
★ For the front output shaft speed sensor, see "Disconnection of
front differential and transmission."
5. Torque converter oil temperature sensors

Remove torque converter oil temperature sensors (7) and (8).
6. Torque converter oil pressure sensor

Remove torque converter oil pressure sensor (230).
7. Strainer
Remove strainer (9).
8. Mounting bracket and trunnion

Remove trunnion (10) (on the rear side) and mounting bracket (11)
(on the front differential side).

Disconnect the front differential assembly. For details, see "Discon-
nection of front differential and transmission."
10. Transmission control valve, main relief valve, valve seat and tube
Remove transmission control valve assembly (12), main relief
valve assembly (13), and valve seat (14) and tube (225).
HM400-1L 30-85
11. Coupling
A. Remove rear coupling (15).
B. Remove input coupling (27).
12. Front output shaft snap ring

Remove snap ring (16).
30-86 HM400-1L
13. Covers
Remove covers (18) (on the 1st clutch side) and (19) (on the 2nd
clutch side).
★ Check the thickness and quantity of the shims on the cover (19)
side.
14. Bearing cage
A. Using forcing screw B, remove bearing case (20).

★ Check the thickness and quantity of the shims
B. Remove bearing outer race (38o), dust seal (67), and oil seal
(68) from bearing cage (66).
★ For bearing inner race, see "Disassembly of differential lock
clutch."
15. Transmission case assembly (on opposite side of torque converter)

Place the transmission with the torque converter side down and
remove the transmission case assembly (21) (on the opposite side
of the torque converter).
WARNING! If the transmission is not placed with the

torque converter side down, it cannot be
disassembled. Be sure to set it with the
torque converter side down.
HM400-1L 30-87
★ If the transmission is disassembled with the torque converter
side up, its inside will be broken. Therefore, be sure to disas-
semble the transmission with the torque converter side down.
★ For further disassembly of the transmission case, see "step 27."
16. Shroud
Remove shroud (90).
17. Differential lock clutch assembly

Remove differential lock clutch assembly (22).
★ For further disassembly of the differential lock clutch assem-
bly, see "step 23."
18. FH and 1st clutch assembly and 2nd and 3rd clutch assembly
Lift off FH and 1st clutch assembly (23) and 2nd and 3rd clutch
assembly (24) simultaneously.
★ For further disassembly of the 2nd and 3rd clutch assembly, see
"step 24." For further disassembly of the FH and 1st clutch
assembly, see "step 25."
30-88 HM400-1L
19. R and FL clutch assembly
Remove R and FL clutch assembly (25).
★ For further disassembly of the R and FL clutch assembly, see
"step 26."
20. Cage assembly
A. Using forcing screw C, remove cage assembly (26).
B. Disassemble the cage assembly according to the following pro-

cedure.
i. Remove snap ring (201), then remove bearing and spacer

and snap ring assembly (202).
HM400-1L 30-89
ii. Remove snap ring (203) from bearing and spacer and snap
ring assembly (202), then remove bearing (205) from
spacer (204).
iii. Remove bearing outer race (380) from cage (211).
21. P.T.O. assembly

Remove P.T.O. assembly (28).
★ For further disassembly of the P.T.O. assembly, see "step 28."

Remove the bolts (12 pieces) used to install the torque converter
assembly (29) to the transmission, then remove torque converter
assembly (29).
★ For disassembly of the torque converter assembly, see "Disas-
sembly of torque converter."
30-90 HM400-1L
23. Disassembly of differential lock clutch assembly
A. Using forcing screw D, remove gear and shaft and ring gear
assembly (30).
B. Disassemble the gear and shaft and ring gear assembly accord-
ing to the following procedure.
i. Using push tool 1%, remove shaft and ring gear assembly
(31).
ii.
Remove shaft and snap ring assembly (32), ring gear
assembly (33), and bearing (34) (Inner races: 34-1i, 34-2i,
Spacer: 34-3).
★ Bearing (34) (Inner races: 34-1, 34-2, 34-3) is the assem-
bly number.
★ For bearing outer race (34-1o, 2o), see step iv below.
HM400-1L 30-91
iii. Remove snap rings (36) and (68) from shaft (35).
★ Snap ring (68) is for the oil sump.
iv. Remove gear (37), bearing (34) (Outer races: 34-1o, 34-
2o), and bearing inner race (38).
C. Remove snap ring (39) and sun gear (40)
D. Remove snap ring (41).
30-92 HM400-1L
E. Remove the mounting bolts (12 pieces) and carrier assembly
(42).
F. Disassemble the carrier assembly according to the following

procedure.
i. Remove ring (43).
ii. Drive out shaft (44) toward ball (45) and remove shaft
(44), gear (46), ball (45), bearing (47) (two pieces), and
thrust washers (48) (two pieces).
G. Remove front shaft and hub assembly (49).
HM400-1L 30-93
H. Disassemble front shaft and hub assembly (49) according to
the following procedure.
i. Remove snap ring (50), then remove hub (52) and bearing
inner race (64i) from shaft (51).
ii. Remove seal rings (53) and (54).
I. Remove end plate (55), discs (56) (seven pieces), plate (57)
(seven pieces), and wave springs (58) (seven pieces) from the
differential clutch.
30-94 HM400-1L
J. Using the hanging tap, remove piston assembly (59).
K. Remove seal ring (61) from piston (60).
L. Disassemble the housing assembly according to the following

procedure.
Remove seal ring (63), bearing outer race (64o), and bearing
inner race (65i) from housing (62).
★ For bearing outer race (65o), see "Disassembly of trans-
mission case assembly on torque converter side," (step
28).
HM400-1L 30-95
24. Disassembly of 2nd and 3rd clutch assembly
(2nd clutch side)
A. Remove seal rings (71) (three pieces).
B. Using puller [4], remove spacer (226) and bearing inner race
(73i) together. After removing spacer (227) (two-piece type),
remove gear (72).
C. Remove spacer (74) (two-piece type) and thrust washer (75).
D. Remove gear and needle roller bearing assembly (76).
30-96 HM400-1L
E. Remove needle roller bearing (78) from gear (77).
F. Using a C-clamp, jig f, etc., compress the clutch spring and

remove snap ring (79).
★ The 2nd clutch has a screw hole for eyebolt on the gear.
The clutch spring may be compressed by inserting a spacer
of proper thickness on the clutch side and utilizing that
screw hole.
G. Remove end plate (80), plates (81) (14 pieces), discs (82) (13
pieces), and wave springs (83) (13 pieces) from the 2nd clutch.
HM400-1L 30-97
H. Using the hanging tap, remove thrust washers (84) and piston
assembly (86).
I. Remove seal rings (88) and (89) from piston (87).
(3rd clutch side)
J. Using push puller g, remove bearing inner race (100i) and

spacer (101).
28).
30-98 HM400-1L
K. Remove snap ring (102) and thrust washer (103).
L. Remove gear and needle roller bearing assembly (104).
M. Remove needle roller bearing (106) from gear (105).
HM400-1L 30-99
N. Using C-clamp h, etc., compress the clutch spring and remove

snap ring (107).
★ 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.)
O. Remove end plate (108), plates (109) (eight pieces), discs (110)
(seven pieces), and wave springs (111) (seven pieces) from the
3rd clutch.
30-100 HM400-1L
P. Remove thrust washer (112) and piston assembly (113).
Q. Remove seal rings (115) and (116) from piston (114).
25. Disassembly of 1st and FH clutch assembly

(1st clutch side)
B. Using puller e, remove gear (122) and bearing inner race

(123i) together.
mission case assembly on opposite side of torque con-
verter," (step 27).
HM400-1L 30-101
C. Remove snap ring (124) and thrust washer (125).
D. Remove gear and needle roller bearing assembly (126).
E. Remove needle roller bearing (128) (two pieces) from gear

(127).
30-102 HM400-1L
F. Using C-clamp i, etc., compress the clutch spring and remove

snap ring (129).
shaft and press down the end plate with the spacer.).
G. Remove end plate (130), plates (131) (13 pieces), discs (132)
(12 pieces), and wave spring (133) (12 pieces) from the 1st
clutch.
HM400-1L 30-103
H. Using the hanging tap, remove thrust washers (134) and piston
assembly (136).
I. Remove seal rings (138) and (139) from piston (137).
30-104 HM400-1L
(FH clutch side)
J. Using push puller i, remove gear and needle roller bearing

assembly (140), bearing inner race (141i), spacer (142), and
thrust washer (143) together.
28).
K. Remove needle roller bearing (145) from gear (144).
HM400-1L 30-105
L. Using C-clamp j, etc., compress the clutch spring and remove

snap ring (146).
M. Remove end plate (147), plates (148) (ten pieces), discs (149)
(nine pieces), and wave springs (150) (nine pieces) from the
FH clutch.
30-106 HM400-1L
N. Using the hanging tap, remove thrust washer (151) and piston
assembly (152).
O. Remove seal rings (154) and (155) from piston (153).
26. Disassembly of R and FL clutch assembly

(R clutch side)
B. Using push puller 1), remove gear and needle roller bearing
assembly (162), bearing inner race (163i), spacer (164), and
thrust washer (165) together.
verter," (step 27).
HM400-1L 30-107
C. Remove needle roller bearing (167) from gear (166).
D. Using C-clamp 1!, etc., compress the clutch spring and remove
snap ring (168).
30-108 HM400-1L
E. Remove end plate (169), plates (170) (12 pieces), discs (171)
(11 pieces), and wave springs (172) (11 pieces) from the R
clutch.
F. Remove thrust washer (173) and piston assembly (174).
G. Remove seal rings (176) and (177) from piston (175).
HM400-1L 30-109
(FL clutch side)
H. Using push puller E, remove gear (178) and bearing inner race
(179i) together.
I. Remove spacer (180) (two-piece type) and thrust washer (181),

then remove gear and needle roller bearing (182) assembly.
J. Remove needle roller bearing (184) from gear (183).
30-110 HM400-1L
K. Using C-clamp 1!, etc., compress the clutch spring and remove
snap ring (185).
shaft and press down the end plate with the spacer.).
L. Remove end plate (186), plates (187) (12 pieces), discs (188)
(11 pieces), and wave springs (189) (11 pieces) from the FL
clutch.
HM400-1L 30-111
M. Remove thrust washer (190) and piston assembly (191).
N. Remove seal rings (193) and (194) from piston (192).
27. Disassembly of transmission case assembly (on opposite side of

torque converter)
A. Remove holder (213), gear (214), bearings (215) and (216),

snap ring (217), and collar (218).
B. Remove bearing outer races (73o), (123o), and (163o).
30-112 HM400-1L
28. Disassembly of transmission case assembly (on torque converter
side)
Remove bearing outer races (64o), (100o), and (141o) from the
case.
29. Disassembly of P.T.O. case assembly

Disassemble the three idle gear according to the following proce-
dure.
A. Remove nut (219) and P.T.O. gear and bearing inner race
assembly (220).
B. Remove bearing inner race (222ir) from P.T.O. gear and bear-
ing inner race assembly (221).
C. Remove snap ring (223), plate (224), bearing (222l), spacer

(222c), and bearing outer race (222or).
HM400-1L 30-113
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF TRANSMISSION
ASSEMBLY OF TRANSMISSION
● Precautions for assembly
★ Clean all the parts and check them for dirt or damage before
installing.
★ Coat the sliding surfaces of the all parts with engine oil before
installing.
★ Dip the discs in clean engine oil (EO-30CD) for at least two
minutes before installing.
★ Install seal ring (a) for the piston with the pressure receiving
side (side "b") directed to housing (c) as shown in the figure.
1. Assembly of P.T.O. case assembly
A. Install bearing outer race (222or), spacer (222c), and bearing

(222ol), then fix them with plate (224) and snap ring (223).
B. Set bearing inner race (222il) in position and install P.T.O. gear
(221) and press fit it by tightening nut (219).
Bolt: Adhesive (LT-2)
Bolt: 313.8 - 392.3 N•m
2. Assembly of transmission case assembly (on torque converter side)

Install bearing outer races (64o), (100o), and (141o) to the case.
30-114 HM400-1L
3. Assembly of transmission case assembly (on opposite side of
torque converter)
A. Install bearing outer races (73o), (123o), and (163o).
B. Fit collar (218) and install bearings (215) and (216) to gear
(214) by expansion fit.
★ Follow the installation directions carefully.
C. Install snap ring (217).
D. Install gear assembly (214) by shrink fit.

★ Shrink fit temperature: Approximately 120°C for 30 minutes.
E. Install holder (213) and tighten the bolts.
Bolt: Adhesive (LT-2)
Bolt: 313.8 - 392.3 N•m
4. Assembly of R and FL clutch assembly

(FL clutch side)
A. Install seal rings (193) and (194) to piston (192).

★ Install the seal rings with the pressure receiving side
directed to the housing.
B. Install piston assembly (191) and thrust washer (190).
Bolt: Apply engine oil (EO-30CD) to the periphery and con-

tact surfaces of the seal rings.
HM400-1L 30-115
C. Install plates (187) (12 pieces), discs (188) (11 pieces), wave
springs (189) (11 pieces), and end plate (186) to the FL clutch.
D. Install needle roller bearing (184) (two pieces) to gear (183).
E. Install gear and needle roller bearing assembly (182) tempo-

rarily and match the grooves of the discs.
★ Pressing down the assembly, turn it to the right and left
and push it in gradually so that it will not collide with the
crests of the discs.
30-116 HM400-1L
F. Remove the gear and needle roller bearing assembly (182).
G. Using C-clamp 1!, etc., compress the clutch spring and install
snap ring (185).
H. Install gear and needle roller bearing assembly (182), thrust

washer (181), and spacer (180) (two-piece type).
★ If the gear and needle roller bearing assembly (182) is dif-
ficult to install, repeat the procedure from step E.
★ 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 (184).
I. Install gear (178), then install bearing inner race (179i) by

shrink fit.
★ Shrink fit temperature: Approximately 120°C for 30 min-
utes.
verter," (step 27).
HM400-1L 30-117
(R clutch side)
J. Install seal rings (176) and (177) to piston (175).

K. Install piston assembly (174) and thrust washer (173).
Apply engine oil (EO-30CD) to the periphery and contact

surfaces of the seal rings.
30-118 HM400-1L
L. Install plates (170) (12 pieces), discs (171) (11 pieces), wave
springs (172) (11 pieces), and end plate (169) to the R clutch.
★ Dip the discs in clean engine oil (EO-30CD) for at least
two minutes before installing.
M. Install needle roller bearing (167) (two pieces) to gear (166).
N. Install gear and needle roller bearing assembly (162) temporarily

and match the grooves of the discs.
HM400-1L 30-119
O. Remove the gear and needle roller bearing assembly (162).
P. Using C-clamp, jig 1!, etc., compress the clutch spring and
install snap ring (168).
Q. Install gear and needle roller bearing assembly (162), thrust washer
(165), and spacer (164).
★ If gear and needle roller bearing assembly (162) is difficult to
install, repeat the procedure from step N.
R. Install bearing inner race (163i) by shrink fit.

★ Shrink fit temperature: Approximately 120° C for 30 min-
utes.
★ For bearing outer race (163o), see assembly of transmis-
sion case assembly on opposite side of torque converter.
30-120 HM400-1L
S. Install seal rings (161) (three pieces).
5. Assembly of 1st and FH clutch assembly

(FH clutch side)


★ Using the hanging tap, install piston assembly (152), tak-
ing extreme care that the seal rings will not be caught.

HM400-1L 30-121
C. Install plates (148) (ten pieces), discs (149) (nine pieces), wave
springs (150) (nine pieces), and end plate (147) to the FH
clutch.
D. Install needle roller bearing (145) to gear (144).
E. Install gear and needle roller bearing assembly (140) tempo-

30-122 HM400-1L
F. Remove the gear and needle roller bearing assembly (140).
G. Using C-clamp J, etc., compress the clutch spring and install

snap ring (146).
H. Install gear and needle roller bearing assembly (140), thrust

washer (143), and spacer (142).
★ If the gear and needle roller bearing assembly (140) is dif-
ficult to install, repeat the procedure from step E.
I. Install bearing inner race (141i) by shrink fit.

utes.
verter," (step 27).
HM400-1L 30-123
(1st clutch side)
J. Install seal rings (138) and (139) to piston (137).

K. Install piston assembly (136) and thrust washer (134).

★ Using the hanging tap, install piston assembly (136), tak-
ing extreme care that the seal rings will not be caught.

30-124 HM400-1L
L. Install plates (131) (12 pieces), discs (132) (11 pieces), wave
springs (133) (11 pieces), and end plate (130) to the 1st clutch.
M. Install needle roller bearing (128) (two pieces) to gear (127).
N. Install gear and needle roller bearing assembly (126) tempo-

HM400-1L 30-125
O. Remove the gear and needle roller bearing assembly (126).
P. Using C-clamp, jig I, etc., compress the clutch spring and

Q. Install gear and needle roller bearing assembly (126).

★ If the gear and needle roller bearing assembly is difficult
to install, repeat the procedure from step M.
R. Install thrust washer (125) and snap ring (124).
30-126 HM400-1L
S. Install gear (127).
T. Install bearing inner race (123i) by shrink fit.

utes.
verter," (step 27).
U. Install seal rings (121) (three pieces).
6. Assembly of 2nd and 3rd clutch assembly

(3rd clutch side)


HM400-1L 30-127
C. Install plates (109) (eight pieces), discs (110) (seven pieces),
wave springs (111) (seven pieces), and end plate (108) to the
3rd clutch.
D. Install needle roller bearing (106) to gear (105).
E. Install gear and needle roller bearing assembly (104) temporarily

and match the grooves of the discs.
F. Remove gear and needle roller bearing assembly (104) again.
30-128 HM400-1L
G. Using C-clamp H, etc., compress the clutch spring and install

snap ring (107).
H. Install gear and needle roller bearing assembly (104).

★ If it is difficult to install the gear and needle roller bearing
assembly, repeat the procedure from step E.
I. Install thrust washer (103) and snap ring (102).
J. Install spacer (101), then install bearing inner race (100i) by

shrink fit.
utes.
HM400-1L 30-129
(2nd clutch side)
K. Install seal rings (88) and (89) to piston (87).

L. Install piston assembly (86) and thrust washer (84).

★ Using the hanging tap, install piston assembly (86), taking
extreme care that the seal rings will not be caught.

30-130 HM400-1L
M. Install plates (81) (14 pieces), discs (82) (13 pieces), wave
springs (83) (13 pieces), and end plate (80) to the 2nd clutch.
N. Install needle roller bearing (78) to gear (77).
O. Install gear and needle roller bearing assembly (76) tempo-

HM400-1L 30-131
P. Remove the gear and needle roller bearing assembly (76).
Q. Using C-clamp, jig f, etc., compress the clutch spring and

★ The 2nd clutch has a screw hole for eyebolt on the gear.
The clutch spring may be compressed by inserting a spacer
of proper thickness on the clutch side and utilizing that
screw hole.
R. Install gear and needle roller bearing assembly (76).

★ If the gear and needle roller bearing assembly is difficult to
install, repeat the procedure from step M.
S. Install gear (73), spacer (227) (two-piece type), and spacer (226)
(having a spline).
30-132 HM400-1L
T. Install bearing inner race (73i) by shrink fit.
utes.
U. Install seal rings (71) (three pieces).
7. Assembly of differential clutch assembly
A. Assemble the housing assembly according to the following

procedure.
i.Using push tool 1@, press fit bearing inner race (65i) to
housing (62).
28).
ii. Using push tool 1#, press fit bearing outer race (64o) to
housing (62).
HM400-1L 30-133
iii. Install seal ring (63).
★ Install the seal ring with the pressure receiving side
B. Install seal ring (61) to piston (60).
Apply grease (G2-L1) to the seal ring.
★ Install the seal ring with the pressure receiving side

C. Install piston assembly (59).

★ Using the hanging tap, install piston assembly (59), taking
extreme care that the seal rings will not be caught.
D. Assemble front shaft and hub assembly (49) according to the

following procedure.
i. Using push tool 1$, press fit bearing inner race (64i) to
shaft (51).
30-134 HM400-1L
ii. Install hub (52) to shaft (51), then install snap ring (50).
iii. Install seal rings (53) and (54).
Apply grease (G2-L1) to the seal rings.
E. Install front shaft and hub assembly (49).
HM400-1L 30-135
F. Install plates (57) (seven pieces), discs (56) (seven pieces),
wave springs (58) (seven pieces), and end plate (55) to the dif-
ferential clutch.
G. Assemble the carrier assembly according to the following pro-

cedure.
i.Set gear (46), bearings (47) (two pieces) and thrust wash-
ers (48) (two pieces) in position and drive in shaft (44)
halfway and put in ball (45), then drive shaft (44) to the
end.
★ First, adjust the position (direction) of the hole to put the
ball in.
ii. Install ring (43).
30-136 HM400-1L
H. Install carrier assembly (42).
I. Install snap ring (41).
J. Install sun gear (40) and snap ring (39).
K. Assemble the gear and shaft and ring gear assembly according
to the following procedure.
i. Install snap rings (68) and (36) to shaft (35).

★ Snap ring (68) is for the oil sump.
HM400-1L 30-137
ii. Press fit bearing inner race (38i) to gear (37).
★ For bearing outer race (38o), see the section of bearing
cage.
iii. Using push tool 1^, press fit bearing outer race (34-2o) to
gear (37).
★ Bearing (34) (Inner races: 34-1, 34-2, 34-3) is the assem-
bly number.
iv. Install shaft and snap ring assembly (32) to ring gear (33).
v. Set the snap ring side of shaft and snap ring assembly (32)
as the receiver and press fit (install) ring gear (33) and
bearing inner race (34-2i) together, using push tool 1&.
30-138 HM400-1L
vi. Install spacer (34-3) to shaft and ring gear assembly (69).
vii. Set the snap ring side of shaft and snap ring assembly (32)
as the receiver and press fit (install) gear assembly (70)
and bearing inner race (34-1i) together, using push tool
1*.
viii. Install gear and shaft and ring gear assembly (30).

Install torque converter assembly (29).
★ For assembly of the torque converter, see Assembly of torque

converter.
HM400-1L 30-139
9. P.T.O. assembly
Install the O-ring and P.T.O. assembly (28).
O-ring on mating face: Grease (G2-L1)
★ For assembly of the P.T.O. assembly, see Assembly of P.T.O.
10. Cage assembly
A. Assemble the cage assembly according to the following proce-

dure.
i. Install bearing outer race (380) to cage (211).
30-140 HM400-1L
ii. Using push tool 1(, press fit bearing (205) to spacer (204)
and install snap ring (203).
iii. Install bearing and spacer and snap ring assembly (202),
then install snap ring (201).
HM400-1L 30-141
B. Install cage assembly (26).
O-ring on mating face: Grease (G2-L1)
11. R and FL clutch assembly

Install R and FL clutch assembly (25).
★ For assembly of R and FL clutch assembly, see step 4.
Apply grease (G2-L1) to the seal rings (three places) before

installing transmission case (21) (on the opposite side of the
torque converter).
★ Check that the cuts of the seal rings (three places) are not
opened.
12. 1st and FH clutch assembly and 2nd and 3rd clutch assembly
Sling and install 1st and FH clutch assembly (23) and 2nd and 3rd
clutch assembly (24) simultaneously.
★ For assembly of the 1st and FH clutch assembly, see step 5. For
assembly of the 2nd and 3rd clutch assembly, see step 6.
Apply grease (G2-LI) to the seal rings (six places) before

installing transmission case assembly (21) (on the opposite
side of the torque converter).
★ Check that the cuts of the seal rings (six places) are not opened.
13. Differential lock clutch assembly

Install differential lock clutch assembly (22).
★ For assembly of the differential lock clutch assembly, see step
7.
30-142 HM400-1L
14. Shroud
Install shroud (90).
★ Press the shroud lightly against the housing, then separate it
from the housing by 1 mm and install it.
15. Transmission case assembly (on opposite side of torque converter)

Install transmission case assembly (21) (on the opposite side of the
torque converter).
★ For assembly of the transmission case (on the opposite side of the
torque converter), see step 3.
16. Bearing cage
A. Bearing cage (2nd side)

Install outer race (129) to bearing cage (128).
B. Bearing cage (Rear output side)

Using push tool 2), press fit oil seal (68) to bearing cage (66).
★ Adjust distance "f" from the cage end to 28.5 ± 0.2 mm.
HM400-1L 30-143
C. Using push tool 2), press fit oil seal (67) to bearing cage (66).
★ Adjust distance "g" from the cage end to 13.5 ± 0.2 mm.
D. Install bearing outer race (38o).
17. Procedure for installing bearing cage and adjusting preload on

tapered roller bearing
A. Engage the differential lock clutch with air.

★ Keep the differential lock clutch engaged until the following
adjustment of the shim is completed.
B. Install bearing cages (19) and (20) without shims.
C. Rotate the output shaft 20 turns.
D. Check that the tightening torque of the mounting bolt has not
changed. If it has changed, repeat steps A and B.
E. Loosen the mounting bolts of bearing cage (19) and measure

the rotating torque of the output shaft.
★ Rotating torque: 14.7 - 25.5 Nm
F. Measure clearance "f" between bearing cage (19) and rear

transmission case at three places (equally spaced on the periph-
ery) and obtain the average.
30-144 HM400-1L
G. Subtract the following value from the average of clearance "a" obtained earlier in step F above. Insert shims of the
thickness equivalent to the result of this calculation.
★ Reduction of thickness: 0.10 - 0.15 mm
★ Allowable range of shim thickness (Reference): 1.7 - 3.0
mm
H. Rotating the output shaft, tighten the mounting bolts of bearing

cage (19) to the following torque.
Mounting bolt: 98 - 122 N•m
I. Measure the rotating torque of the output shaft and check that
its increase from the value obtained in step E is in the follow-
ing range: 2.94 - 9.81 Nm.
J. Measure clearance "a" between bearing cage (20) and the rear
transmission case at three places (equally spaced on the periph-
ery) and obtain the average.
★ If the dispersion of the measured values at the three places
exceeds 0.15 mm, check the bearing and other parts for
abnormality. Correct any abnormal part and measure
clearance "a" again.
K. Subtract the following value from the average of clearance "f"

obtained in step J above. Insert shims of the thickness equiva-
lent to the result of this calculation.
★ Reduction of thickness: 0.05 - 0.10 mm
★ Allowable range of shim thickness (Reference):1.50 - 3.15
mm
L. Rotating the output shaft, tighten the mounting bolts of bearing cage
(20) to the following torque.
M. Measure the rotating torque of the output shaft and check that
its increase from the value obtained in step I is in the following
range.
★ Increase of rotating torque: 2.94 - 9.81 Nm
HM400-1L 30-145
N. Install cover (18) (1st clutch side).
18. Snap ring of front output shaft

Install snap ring (16).
19. Coupling
A. Install the O-ring, holder, and rear coupling (15).
Mounting bolt: 824 - 1,030 N•m
30-146 HM400-1L
B. Install input coupling (27).
Fitting part of O-ring: Grease (G2-L1)
20. Transmission control valve, torque converter valve, valve seat and
tube
A. Install transmission case upper tube (130).

★ Take care not to mistake the direction of the tube.
B. Install the O-ring, valve seat (14), transmission control valve assem-
bly (12), and main relief valve assembly (13).
Mounting bolt marked * (two pieces): 34 - 44 N•m

(Others must conform to KES)

Couple the front differential assembly. For details, see "Coupling
front differential with transmission."
22. Mounting bracket and trunnion

Install mounting bracket (11) (on the front differential side) and
trunnion (10) (on the rear side).
Mounting bolt of mounting bracket (11) (on front differential

side): Adhesive (LT-2)
Mounting bolt of mounting bracket (11) (on front dif-

ferential side: 455 - 566 N•m
23. Strainer
Install strainer (9).
24. Torque converter oil pressure (pickup) sensor

Install torque converter oil pressure (pickup) sensor (230).
Threaded parts of oil pressure sensor:

Gasket sealant (LG-5)
HM400-1L 30-147
25. Torque converter oil temperature sensors
Install torque converter oil temperature sensors (6) and (7).
Threaded parts: Gasket sealant (LG-5)
Threaded parts: 15.7 - 19.2 N•m
26. Transmission speed sensors

Install transmission input shaft speed sensor (4), intermediate shaft
speed sensor (5), and rear output shaft speed sensor (6).
★ For adjustment method and tightening torque, see TESTING
AND ADJUSTING.
★ For the front output shaft speed sensor, see Separation 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).
30-148 HM400-1L
29. Piping
Install piping (1).
HM400-1L 30-149
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT DIFFERENTIAL
DISASSEMBLY OF FRONT DIFFER-

ENTIAL
1. Speed sensor and top cover
Remove speed sensor (1) and top cover (2).
2. Bevel gear supporting bolt

Remove bevel gear supporting bolt (4).
3. Pinion and case assembly
A. Using forcing screw B, remove pinion and case assembly (9).

★ Check the thickness and quantity of the shims.
30-150 HM400-1L
B. Disassemble pinion and case assembly (9) according to the fol-
lowing procedure.
i. Remove case assembly (10) from pinion assembly (11).
ii. Remove spacer (12) and bearing inner race (13i).
iii. Remove seals (14) and (15), bearing (16), and bearing
outer race (13o) from case (11).
HM400-1L 30-151
4. Input shaft coupling and holder
Remove holder (5) and coupling and gear assembly (6).
5. Right and left output shaft couplings

Remove couplings (17) and (18) on both sides.
6. Side carrier and shaft assembly
A. Sling the differential gear case with wires and remove side car-
rier and shaft assembly (19) on the bevel gear side by using
forcing screw B.
30-152 HM400-1L
B. Under the above condition, remove side carrier and shaft
assembly (20) on the opposite side by using forcing screw
C.
★ Check the thickness and quantity of the shims and the
position of the side carrier.
★ For disassembly of side carrier and shaft assembly, see 8.
7. Differential gear and differential lock assembly
A. Remove the mounting bolts (21) (three pieces) from the

retainer of the differential gear case, then remove differential
gear and differential lock assembly (22).
HM400-1L 30-153
B. Disassemble the differential gear and differential lock assem-
bly according to the following procedure.
i. Using pullers D (10 t) and E, remove retainer (23) and

bearing inner race (24i).
30-154 HM400-1L
ii. Remove seal ring (25).
iii. Remove case and piston assembly (26).
iv. Remove piston (28) from case (27).

★ Piston (28) may be left below (on the differential case
side). In that case, remove the piston separately.
v. Remove seal ring (29) from piston (28).

★ Check the direction of the seal ring.
HM400-1L 30-155
vi. Remove seal ring (30) and thrust washer (68) from case
(27).
vii. Remove plate (31), disc (32), and pin (33).
viii. Bevel gear assembly

● 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).
★ 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).
30-156 HM400-1L
● Using puller F, remove bearing inner race (38i) from

bevel gear and case assembly (37).
● Remove case (39) from bevel gear (40).
ix. Remove washer (41) and differential side gear (42).
HM400-1L 30-157
x. Remove pinion gear assembly (43) and cross shaft (44) in
one unit.
xi. Remove washer (45), pinion gear (46), and bushing

(sleeve) (47).
xii. Remove side gear (48).
30-158 HM400-1L
8. Disassembly of side carrier and shaft assembly
A. Disassemble the side carrier and shaft assembly on the bevel

gear side according to the following procedure.
i. Remove seal (49).
ii. Shaft and bearing inner race assembly

● Remove shaft and bearing inner race assembly (50).
● Using push tool G, remove bearing inner race (51i).
iii. Remove bearing (53) and bearing outer races (38o) and
(51o) from case (52).
★ Bearing (53) is divided into the inner race and outer race
when the shaft is removed (pulled out).
HM400-1L 30-159
B. Disassemble the side carrier and shaft assembly on the oppo-
site side of the bevel gear according to the following proce-
dure.
i. Remove seal (54).

● Remove shaft and bearing inner race assembly (55).
● Using push tool H, remove bearing inner race (56i).
iii. Remove bearing (58) and bearing outer races (24o) and
(56o) from case (57).
★ Bearing (58) is divided into the inner race and outer race
when the shaft is removed (pulled out).
30-160 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT DIFFERENTIAL
ASSEMBLY OF FRONT DIFFERENTIAL

★ When installing a seal to another part (particularly when installing
it to the input shaft), use a push tool matched to the diameter of that
seal, even if use of the push tool is not described in this manual.
1. Assembly of side carrier and shaft assembly
A. Assemble the side carrier and shaft assembly on the bevel gear
side according to the following procedure.
i. Install bearing outer races (38o), (51o), and (53o) to case

(52).

● Using tool H4, press fit bearing inner race (51i) to shaft
(59).
● Set the standard shims (having the thickness and quantity

checked when disassembled) and install coupling (17).
Using push tool H, press holder (60) to press fit case
assembly (61) to shaft and bearing inner race assembly
(50).
HM400-1L 30-161
● Adjust the shims for the bearing according to the follow-
ing procedure.
a) Measure the starting tangential force in the tangen-
tial direction of the bolt hole (φ234) of the case.
★ Standard tangential force: Max. 21.5 N
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.
★ If the starting tangential force is too large, disassemble
shaft and bearing inner race assembly (50) and case
assembly (61) and increase the shims, then execute the
bullet statement before this one.
iii. Using tool H3, press fit seal (49).
B. Assemble the side carrier and shaft assembly on the opposite

side of the bevel gear according to the following procedure.
i. Install bearing outer races (24o), (56o), and (58o) to case

(57).
30-162 HM400-1L
● Using tool H4, press fit bearing inner race (56i) to shaft
(63).
● Set the standard shims (having the thickness and quantity

checked when disassembled) and install coupling (18).
Using push tool H, press holder (65) to press fit case
assembly (66) to shaft and bearing inner race assembly
(55).
● Adjust the shims for the bearing according to the follow-

ing procedure, similarly to the side carrier on the bevel
gear side.
a. Measure the starting tangential force in the tangential
direction of the bolt hole (φ208) of the case.
★ Standard tangential force: Max. 24.5 N
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.
★ If the starting tangential force is tool large, disassemble
shaft and bearing inner race assembly (55) and case
assembly (65) and increase the shims, then execute the
bullet statement before this one.
iii. Using tool H3, press fit seal (54).
HM400-1L 30-163
★ The procedure for installing both side carrier and shaft assemblies
to the body is explained in step 3 (Side carrier and shaft assembly)
below.
A. Assemble the differential gear and differential lock assembly

according to the following procedure.
i. Install side gear (48).
ii. Install bushing (sleeve) (47), pinion gear (46), and washer
(45).
iii. Install pinion gear assembly (43) and cross shaft (44) in
one unit.
30-164 HM400-1L
iv. Install differential side gear (42) and washer (41).
v. Bevel gear assembly

● Install case (39) to bevel gear (40).
● Install bearing inner race (38i) to bevel gear and case

assembly (37) by shrink fit.
★ Shrink fit temperature: 120° C for 30 minutes
● Install bevel gear assembly (35) to case (34).

★ Match the match marks to each other.
HM400-1L 30-165
vi. Install pin (33), plate (31), and disc (32).
★ Apply engine oil (EO-30) to the surfaces of the disc and
plate.
vii. Install seal ring (30) and thrust washer (68) to piston case
(27).
★ When installing the seal ring, take care of its direction.
viii. Install seal ring (29) to piston (28).

ix. Install piston (28) to case (27).
30-166 HM400-1L
x. Install case and piston assembly (26).
xi. Install seal ring (25).

xii. Using push tool J, press fit bearing inner race (24i) and
retainer (23) in one unit.
HM400-1L 30-167
B. Sling differential gear and differential lock assembly (22) and
install it to differential gear case (67) and tighten the retainer
mounting bolts (21) (three pieces).
3. Side carrier and shaft assembly
A. Sling the differential gear case and set the standard shims (hav-
ing the thickness and quantity checked when disassembled)
and install side carrier and shaft assembly (19) on the bevel
gear side.
B. Under the above condition, set the standard shim (having the
thickness and quantity checked when disassembled) and install
side carrier and shaft assembly (20) on the opposite side.
30-168 HM400-1L
C. Adjusting preload on side bearing
i.Measure the initial rotating force of the periphery of the

bevel gear in the tangential direction.
★ Initial rotating force: 6.86 - 25.0 N
ii.
If the rotating force is larger than the standard level,
increase the thickness/quantity of the shims. If the former
is in the standard range, it is normal.
★ 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, however.
D. After adjusting the preload, be sure to tighten the mounting

bolts to the specified torque in A.
4. Right and left output shaft couplings

Install couplings (17) and (18) on both sides.
5. Pinion and case assembly
A. Assemble pinion and case assembly (9) according to the fol-

lowing procedure.
i. Using push tool 1), install bearing outer race (13o) to case
(11).
ii. Using push tool 1!, install bearing outer race (16o) to case
(11).
HM400-1L 30-169
iii. Using tool H1, press fit bearing inner race (13i) to pinion
(10).
iv. Install spacer (12).
B. Using tool H1, press fit case assembly (11) to pinion (10).
★ Never push the case assembly with a press.
★ Press fit bearing inner race (16i) with tool H1.
★ Press fitting force: 0 - 8134 N
★ Press fit case assembly (11), turning it.
i. Using push tool 1@, press fit seal (15) to case (11).
Apply Loctite 242 to the periphery of the seal.
★ Taking care of the direction of the seal, press fit it until it is

flush with the case as shown in the figure.
★ Press fit the seal so that standard dimension "a" will be
110 m.
ii. Using tool H2, press fit seal (14) to case (11).
30-170 HM400-1L
Apply Loctite 242 to the periphery of the seal.
★ Taking care of the direction of the seal, press fit it until it is

flush with the case as shown in the figure.
C. Set the standard shim (having the thickness and quantity

checked when disassembled) and install pinion and case
assembly (9).
★ Tighten three mounting bolts first.
★ After adjusting the tooth contact, tighten the all mounting
bolts.
6. Input shaft coupling and holder
A. Using push tool 1#, press fit speed detection gear (8) to cou-
pling (7).
★ Press fit the gear until it is flush with the coupling.
B. Install coupling and gear assembly (6) and holder (5).

Hold end (Face to be in contact with bearing at bottom:
Adhesive (LMP)
Hold mounting bolt: Adhesive (LT-2)
Holder mounting bolt: 824 - 1,030 N•m
HM400-1L 30-171
7. Adjusting tooth contact and backlash
Adjust the backlash and tooth contact simultaneously.
A. Adjust the backlash according to the following procedure.
i. Move the bevel gear with the shims (69) and (70) of both
carrier assemblies. At this time, do not change the total
quantity and thickness of the shims on both sides so that
the preload on the bearing will not change
Apply dial gauge 1# perpendicularly to the reversing tooth

ii.
surface at the outer end of the bevel gear. Adjust the back-
lash so that the gauge will indicate 0.3 - 0.4mm.
★ Adjust the backlash at three to four places and measure it
with the pinion fixed. Do not change the total quantity and
thickness of the shims on both sides so that the given pre-
load will not change.
B. Adjust the tooth contact according to the following procedure.
i. Adjust the projection of the bevel pinion with shim (71)

between the differential case and bearing case.
ii. Adjusting tooth contact

★ See Adjusting tooth contact in step iii below.
iii. Adjusting tooth contact of bevel gear and bevel pinion
30-172 HM400-1L
Testing
A. Apply red lead thinly to the tooth surfaces of the bevel pinion
and turn the bevel gear in the forward and reverse directions,
then check the tooth contact pattern on the bevel gear.
B. The center of the tooth contact must be at the middle of the

tooth height and about 33% (b) of tooth depth from the small
end. The width of the tooth contact must be 30 - 60% (a) of the
tooth depth. Check that there is not a strong contact at the tips
or bottoms of the teeth of both small end and large end.
★ If the bevel gear and bevel pinion are adjusted in this way,
their teeth come in contact with each other correctly when
they are loaded.
HM400-1L 30-173
Adjusting
If the tooth contact pattern is not proper, adjust it according to the fol-
lowing procedure.
1. If the bevel pinion is too far from the center line of the bevel gear,
the contact is at the small end of the bevel gear tooth surfaces
curved outward and at the large end of the bevel gear tooth surfaces
curved inward.
● In this case, adjust the tooth contact according to the following
procedure. Adjust the thickness of the shims on the bevel pin-
ion side to move the bevel pinion in direction A. Adjust the
thickness of the shims of both carrier assemblies to move the
bevel gear in direction B, then check the tooth contact pattern
and backlash again.
2. If the bevel pinion is too close to the center line of the bevel gear,
contact is at the large end of the bevel gear tooth faces curved out-
ward and the small end of the bevel gear tooth faces curved inward.
● In this case, adjust the tooth contact similarly to step 1 above.
Reverse directions A and B, however.
● If the shim on either side is reduced to adjust the projection of
the bevel gear, increase the shim on the opposite side by the
same quantity so that the preload on the bearing will not
change.
● After adjusting the tooth contact, refer to the sections of the
mounting bolts of both bevel gear side carriers, both output
shaft couplings, pinion and case assembly, and input shaft and
observe the application of adhesive and tightening torque.

Install bevel gear supporting bolt (4).
★ 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.
Bolt: Gasket sealant (LG-5)
Locknut: 196 - 245 N•m
4. Speed sensor and top cover

Install speed sensor (1) and top cover (2).
Top cover: Gasket sealant (LT-515)
Top cover: 157 - 196 N•m
30-174 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER DIFFERENTIAL
REMOVAL OF CENTER DIFFERENTIAL

WARNING! Raise the dump body and insert the

safety 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).
3. Drive shaft between hitch frame and center differential

Remove the guard and disconnect only the center differential end of
drive shaft (2) between hitch frame and center differential.
Drive shaft between hitch frame and center differen-

tial (only center differential end): 35 kg (77 lbs)
★ Make match marks so that the spline will not shift in the cir-
cumferential direction.
4. Drive shaft between center differential and rear differential

drive shaft (3) between center differential and rear differential.
HM400-1L 30-175
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER DIFFERENTIAL
5. Coupling on rear differential side
Remove the holder, coupling (4) on the rear differential side, and
cover (5).
6. Rear differential drive shaft and bearing cage assembly

Using forcing screw B, remove rear differential drive shaft (7) and
bearing cage assembly (6) in one unit.
7. Piping and wiring harness

Disconnect differential lock hoses (8) - (10), brake hose (11), brake
cooling hoses (12) (three pieces), and rear retarder oil temperature
sensor connector (CN-T14) (13), then remove brake cooling tube
(14).
8. Center differential assembly

Sling center differential (15) temporarily. Using forcing screws
(M14 x 2), pull out the center differential. After pulling out the dif-
ferential halfway, change the slinging position (increase the number
of slings) and remove the differential.
Center differential assembly: 380 kg (838 lbs)
30-176 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER DIFFERENTIAL
INSTALLATION OF CENTER DIFFERENTIAL

Mounting bolt of drive shaft between hitch frame and center

differential: Adhesive (LT-2)
Mounting bolt of drive shaft between hitch frame and

center differential: 157 - 198 N•m
Target: 177 N•m
★ When installing the drive shaft, check that the key way of the spider
Mounting bolt of drive shaft between center differential and

rear differential: Adhesive (LT-2)
Mounting bolt of drive shaft between center differen-

tial and rear differential: 98 - 123 N•m
Target: 113 N•m
★ When installing a seal to a cover, use a push tool matched to the

diameter of that seal.
Seal lip: Grease (G2-L1)
Mounting bolt cover: 98 - 123 N•m
★ Install the rear (output) coupling so that the phase difference

between it and the front (input) coupling will be 6° or less.
Coupling holder mounting bolt: Adhesive (LT-2)
Coupling holder mounting bolt: 490 - 608 N•m

Target: 550 N•m
Center differential mounting bolt: 157 - 198 N•m

Target: 177 N•m
HM400-1L 30-177
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER DIFFERENTIAL

cuit.
Refilling with oil
● Pour the specified oil in the center differential case and final drive
case to the specified level.
● Check the oil level in the transmission case and add the specified
oil to the specified level if necessary.
● Check the oil level in the hydraulic tank and add the specified oil to
the specified level if necessary.
30-178 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER DIFFERENTIAL
DISASSEMBLY OF CENTER DIFFER-

ENTIAL
1. Set the center differential gear assembly to tool H9.
2. Cover
Remove cover (1).
3. Transfer input coupling and holder

Remove holder (2) and coupling (3).
4. Cage
A. Using forcing screw B, remove cage assembly (4).

HM400-1L 30-179
B. Remove side seal (5), oil seal (6), and bearing outer race (7o)
from cage (12).
5. Transfer input shaft and gear assembly
A. Remove transfer input shaft and gear assembly (8).
B. Disassemble transfer input shaft and gear assembly (8) accord-

ing to the following procedure.
● Remove bearing inner race (7i), spacer (11), and gear (12)
from transfer input shaft (9).
6. Input shaft holder

★ Place a wood block, etc. so that the bevel pinion will not fall.
A. Remove holder (13).

30-180 HM400-1L
B. Remove holder (14) and key (15).
7. Transfer case
A. Using forcing screw C, remove transfer case assembly (16).
B. Remove bearing outer race (10o) and bearing (18) from trans-
fer case (17).
HM400-1L 30-181
8. Input gear and spacer
Remove spacer (19) and input gear (20).
★ Check the identification mark (A - J) of the spacer.
9. Cage assembly
A. Using forcing screw D, remove cage assembly (21).

B. Remove bearing outer race (23o) from cage (22).
10. Pinion assembly
A. Remove pinion assembly (24).
30-182 HM400-1L
B. Disassemble pinion assembly (24) according to the following
procedure. Remove bearing inner race (21i) from pinion (25).

★ Sling the differential case in advance.
A. Remove locks (26) and (27).
B. Using tool H6, loosen adjustment nuts (28) and (29) to the
degree that you can turn them with fingers.
C. Loosen bolts (30) (four pieces).
D. 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 assembly.
★ Take care not to drop the bearing outer race.
HM400-1L 30-183
E. Disassemble the differential gear case assembly according to
i. Gear case
a. Set the gear case to a block (Height: Approximately
200 mm).
b. Remove mounting bolts (33) (20 pieces).
c. Lift off case (34) with wires.
d. Remove seal rings (35) and (36) from case (34).
ii. Remove washer (37) and pin (38).
iii. Remove piston (39).

Remove seal ring (40) from piston (39).
iv. Using a bearing puller, remove bearing inner race (41i).
v. Remove sleeve (42).
vi. Remove plate (43) and disc (44).
vii. Remove pins (45) (four pieces).

a. Turn over the assembly and remove mounting bolts
(48) (12 pieces) of bevel gear assembly (47) of case (46),
then remove bevel gear assembly (47).
30-184 HM400-1L
b. Using puller E, remove bearing inner race (50i) from
c. Remove case (51) from bevel gear (52).
HM400-1L 30-185
one unit.

(sleeve) (59).
30-186 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER DIFFERENTIAL
ASSEMBLY OF CENTER DIFFERENTIAL


(57).
HM400-1L 30-187
one unit.

a. Install case (51) to bevel gear (52).
30-188 HM400-1L
b. Install bearing inner race (50i) to bevel gear and case
c. Install bevel gear assembly (47) to case (46).

vi. Turn over the case and install pin (45), disc (44), and plate
(43).
plate.
HM400-1L 30-189
vii. Install seal ring (40) to piston (39).
★ Take care of the direction of the seal ring.
viii. Install seal rings (35) and (36) to case (34).

★ Take care of the direction of the seal rings.
ix. Install pin (38) and washer (37).
x. Install piston (39) to case (34).
xi. Install the case and piston assembly, matching it to the

position of pin (45).
Case mounting bolt: 157 - 196 N•m
xii. Install seal ring (36) to case (34).

★ Take care of the direction of the seal rings.
xiii. Install sleeve (42), taking care not to damage seal ring
(36).
xiv. Install bearing (41) to case (34) by shrink fit.

2. Differential assembly
A. Differential gear assembly
i. Install nuts (28) and (29), matching them to the grooves of

differential case (61).
ii. Sling gear case (62) and install the outer race to the bear-
ing, then install them to differential case (61).
3. Caps
A. Install caps (31) and (32) and tighten bolt (30) temporarily.
B. Using tools F and G, tighten bolt (21).
Bolt: 824 - 1,040 N•m
30-190 HM400-1L
4. Bearing
A. Rotate the adjustment rings (28) and (29) with bar H6 until the
ring gear reaches the pinion gear and the backlash is elimi-
nated.
★ Rotate the bearing sufficiently so that it will come in con-
tact with the other contact surfaces and hit the ring gear
with a copper hammer, etc.
★ Apply sufficient amount of oil to the bearing.
★ If you loosened either adjustment ring by one turn, tighten
the other one by one turn.
B. 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
5. Assembly of transfer input shaft

Assemble transfer input shaft assembly (8) according to the follow-
ing procedure.
● Install gear (12) and spacer (11) to transfer input shaft (9).
Using push tools H and I, press fit bearing inner race (7i).
6. Assembly of cage of transfer input shaft

Assemble cage assembly (4) according to the following procedure.
A. Install bearing outer race (7o).
B. Using push tool J, install oil seal (6).
HM400-1L 30-191
C. Using push tool 1), install side seal (5).
7. Assembly of transfer case

Install bearing outer race (10o) and bearing outer race (18o).
8. Adjusting preload on bearing of transfer input shaft
A. Install input shaft and gear assembly (8) to transfer case (17)
without inserting any shim. Install cage assembly (4) and
tighten mounting bolts (64) (eight pieces) to 113.0 Nm.
★ At this time, tighten mounting bolts (64) repeatedly, rotat-
ing the bearing, until rotation is stabilized.
B. Sling the coupling with a crane and measure the end play after
adjustment with dial gauge 1!. Determine the thickness of the
shims so that end play will be 0 - 0.05 mm.
C. After checking the thickness of the shims, remove input shaft

and gear assembly (8) and cage assembly (4).
30-192 HM400-1L
9. Assembly of bevel pinion assembly
Assemble bevel pinion assembly (8) according to the following
procedure.
● Using push tool 1@, press fit bearing inner race (21i) to pinion
(25).
10. Adjustment of preload on bevel pinion support bearing
A. Install pinion assembly (24).
B. Cage assembly
i. Install bearing outer race (23o) to cage (22).
ii. Install cage assembly (21).
HM400-1L 30-193
C. Input gear and spacer
Install input gear (20) and spacer (19).
★ Install the spacer checked when disassembled.
MD shim Part No. Letter stamped on
Spacer width
thickness range of spacer spacer
0.013 - 0.113 56B-23-16910 A 25.887±0.025
0.114 - 0.213 56B-23-169120 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
D. Transfer case
Install transfer case assembly (16).
H Check that the bearing of the pinion is fitted accurately.
E. Bearing inner race

Using push tool 1#, press fit bearing inner race (18i).
30-194 HM400-1L
F. Input shaft holder
i. Install holder (14) and key (15).
ii. Set the standard shim (having the thickness and quantity
checked when disassembled) and install holder (13).
Mounting bolt: 824 - 1,040 N•m
★ Execute step 11, "Measurement of tooth contact and back-

lash," then determine the quantity and thickness of the
shims.
G. Measurement of turning torque

Measure the starting tangential force (torque) of the input shaft
with push-pull scale 1$ and check that the result is as follows.
★ Starting tangential force (torque)
Starting torque: 514.5 - 1543.5 Ncm
(Measure this torque by putting a wrench to the shaft end
bolt.)

Adjust the backlash and tooth contact simultaneously.
i. Move the bevel gear with the adjustment nuts (28) and
(29). At this time, rotate the nuts on both sides by the same
turns in the same direction so that the preload on the bear-
ing will not change.
HM400-1L 30-195
Apply dial gauge 1$ perpendicularly to the reversing tooth

ii.
surface at the outer end of the bevel gear. Rotate the
adjustment nuts until the dial gauge indicates 0.3 - 0.4mm.
with the pinion fixed.

between differential case (64) and transfer case (17).

★ See Adjusting tooth contact in C below.
C. Adjusting tooth contact of bevel gear and bevel pinion
Testing
i. Apply red lead thinly to the tooth surfaces of the bevel

pinion and turn the bevel gear in the forward and reverse
directions, then check the tooth contact pattern on the
bevel gear.
ii.
The center of the tooth contact must be at the middle of the
tooth height and about 33% (b) of tooth depth from the
small end. The width of the tooth contact must be 30 -
60% (a) of the tooth depth. Check that there is not a strong
contact at the tips or bottoms of the teeth of both small end
and large end.
they are loaded.
30-196 HM400-1L
Adjusting
If the tooth contact pattern is not proper, adjust it according to the
following procedure.
iii. If the bevel pinion is too far from the center line of the
bevel gear, the contact is at the small end of the bevel gear
tooth surfaces curved outward and at the large end of the
bevel gear tooth surfaces curved inward.
● In this case, adjust the tooth contact according to the fol-
lowing procedure.
Adjust the thickness of the shims on the bevel pinion side
to move the bevel pinion in direction A. Adjust the thick-
ness of the shims of both carrier assemblies to move the
bevel gear in direction B, then check the tooth contact pat-
tern and backlash again.
iv. If the bevel pinion is too close to the center line of the
bevel gear, contact is at the large end of the bevel gear
tooth faces curved outward and the small end of the bevel
gear tooth faces curved inward.
● In this case, adjust the tooth contact similarly to iii above.
★ If the shim on either side is reduced to adjust the projec-
tion of the bevel gear, increase the shim on the opposite
side by the same quantity so that the preload on the bear-
12. Transfer input shaft and gear assembly

Install transfer input shaft and gear assembly (8).
13. Cage
A. Install bearing outer race (7o) to cage (10). Using tool H11,
press fit oil seal (6).
★ Press fit oil seal (6) so that clearance "c" between the
periphery of oil seal (6) and cage (10) will be 10 ± 0.5
mm.
HM400-1L 30-197
B. Using tool H5, press fit side seal (5) to cage (10).
★ If the side seal is press fitted with this tool until it is flush
with the cage, it is positioned accurately.
C. Set the standard shims and install cage assembly (4).
14. Transfer input coupling and holder

Install coupling (3) and holder (2).
End of bearing (Part A): Grease (G2-L1)
End of side seal (Part B): Grease (G2-L1)
Mounting bolt holder: Adhesive (LT-2)
Mounting bolt holder: 824 - 1,040 N•m
30-198 HM400-1L
15. Cover
Install cover (1).

★ 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.
★ For disassembly and assembly of the output section of the center

axle transfer, see "Removal, installation of center differential."
HM400-1L 30-199
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL REMOVAL
REAR DIFFERENTIAL REMOVAL


safety 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).

drive shaft (2) between center differential and rear differential.
4. Piping and wiring harness

cooling hoses (7) (three pieces), and rear brake oil temperature sen-
sor connector (CN-T13) (8), then remove brake cooling tube (9).
30-200 HM400-1L
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL INSTALLATION
5. Rear differential assembly
Sling rear differential (10) temporarily. Using forcing screws (M14
x 2), pull out the rear differential. After pulling out the differential
halfway, change the slinging position (increase the number of
slings) and remove the differential.
★ Support the rear differential from its underside, too, with trans-
mission jack B, etc.
★ Since the rear side of the rear differential is a little low, it does
not come out easily. Accordingly, use guide bolt C, etc. to pull
out the rear differential forward carefully.
Rear differential assembly: 280 kg (617 lbs)
REAR DIFFERENTIAL INSTALLATION

● Carry out installation in the reverse order to removal.


Target: 113 N•m
Rear differential mounting bolt: 157 - 198 N•m

cuit.
Refilling with oil

● Pour the specified oil in the rear differential case and rear final
drive case to the specified level.
HM400-1L 30-201
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR DIFFERENTIAL
DISASSEMBLY OF REAR DIFFEREN-

TIAL
1. Set the rear differential gear assembly to tool H9.
2. Input coupling and holder

Remove holder (1) and coupling (2).
3. Pinion and cage assembly
A. Using forcing screw B, remove pinion and cage assembly (3).

B. Remove side seal (6) and oil seal (7) from pinion and cage
assembly (5).
30-202 HM400-1L
C. Remove pinion assembly (8) from cage assembly (9).
D. Disassembly of pinion assembly

Remove spacer (11) and bearing inner race (12i) from pinion
(10).
E. Disassembly of cage assembly

Remove bearing (14) and bearing outer race (12o) from cage
(13).
★ The inner race of bearing (14) was removed in step C
above.
HM400-1L 30-203
★ Sling the differential case in advance.
A. Remove locks (26) and (27).
B. Using tool H6, loosen adjustment nuts (28) and (29) to the
degree that you can turn them with fingers.
C. Loosen bolts (30) (four pieces).
D. 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 assembly.
★ Take care not to drop the bearing outer race.
E. Disassemble the differential gear case assembly according to

i. Gear case
a. Set the gear case to a block (Height: Approximately
200 mm).
b. Remove mounting bolts (33) (20 pieces).
c. Lift off case (34) with wires.
d. Remove seal rings (35) and (36) from case (34).
ii. Remove washer (37) and pin (38).
iii. Remove piston (39).

● Remove seal ring (40) from piston (39).
iv. Using a bearing puller, remove bearing inner race (41i).
v. Remove sleeve (42).
30-204 HM400-1L
vi. Remove plate (43) and disc (44).
vii. Remove pins (45) (four pieces).

a. Turn over the assembly and remove mounting bolts
(48) (12 pieces) of bevel gear assembly (47) of case (46),
then remove bevel gear assembly (47).
b. Using puller E, remove bearing inner race (50i) from

c. Remove case (51) from bevel gear (52).
HM400-1L 30-205

one unit.

(sleeve) (59).
30-206 HM400-1L
HM400-1L 30-207
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR DIFFERENTIAL
ASSEMBLY OF REAR DIFFERENTIAL


(57).
one unit.
30-208 HM400-1L

a. Install case (51) to bevel gear (52).
b. Install bearing inner race (50i) to bevel gear and case

★ Shrink fit temperature: 120° C for 30 minutes.
c. Install bevel gear assembly (47) to case (46).

HM400-1L 30-209
vi. Turn over the case and install pin (45), disc (44), and plate
(43).
plate.
vii. Install seal ring (40) to piston (39).

a. Take care of the direction of the seal ring.
viii. Install seal rings (35) to case (34).

a. Take care of the direction of the seal rings.
ix. Install pin (38) and washer (37).
x. Install piston (39) to case (34).
xi. Install the case and piston assembly, matching it to the

position of pin (45).
Case mounting bolt: 157 - 196 N•m
xii. Install seal ring (36) to case (34).
xiii. Install sleeve (42), taking care not to damage seal ring
(36).
xiv. Install bearing (41i) to case (34) by shrink fit.

a. Shrink fit temperature: 120° C for 30 minutes.
2. Assembly of differential
A. Differential gear assembly
i. Install nuts (28) and (29), matching them to the grooves of

differential case (61).
ii. Sling gear case (62) and install the outer race to the bear-
ing, then install them to differential case (63).
30-210 HM400-1L
3. Caps
A. Install caps (31) and (32) and tighten bolt (30) temporarily.
B. Using tools F and G, tighten bolt (21).
Bolt: 824 - 1,040 N•m
4. Bearing
A. Rotate the adjustment rings (28) and (29) with bar H6 until the
ring gear reaches the pinion gear and the backlash is elimi-
nated.
★ Rotate the bearing sufficiently so that it will come in con-
tact with the other contact surfaces and hit the ring gear
with a copper hammer, etc.
★ Apply sufficient amount of oil to the bearing.
★ If you loosened either adjustment ring by one turn, tighten
the other one by one turn.
B. 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
5. Assembly of pinion and cage assembly

Assemble pinion and cage assembly (8) according to the following
procedure.
A. Assembly of cage assembly

Install bearing outer races (12o) and (14o) to cage (13).
HM400-1L 30-211
B. Disassembly of pinion assembly
Install bearing inner race (12i) to pinion (10).
★ Install bearing inner race (12i) by shrink fit or by using
push tool H.
C. Erect pinion assembly (8) and insert spacer (11) and install
cage assembly (9).
30-212 HM400-1L
D. Using push tool I and turning cage assembly (9), install bear-
ing inner race (14i).
★ Never push bearing inner race (14i) with a press.
★ Apply oil to bearing inner race (14i).
E. Using tool H11, press fit oil seal (7).

★ Press fit oil seal (7) so that clearance "c" between the
periphery of oil seal (7) and cage (13) will be 10 ± 0.5
mm.
F. Using tool H5, press fit side seal (5).

★ Press fit side seal (5) so that its periphery will be flush
with cage (13).
HM400-1L 30-213
6. Pinion and cage assembly
Set the standard shim (having the thickness and quantity checked
when disassembled) and install pinion and cage assembly (3).
★ Execute Step 8 "Measurement of tooth contact and backlash,"
then determine the quantity and thickness of the shims.
7. Input coupling and holder

Install coupling (2) and holder (1).
End of bearing (Part A): Grease (G2-L1)
End of side seal (Part B): Grease (G2-L1)
Holder mounting bolt: Adhesive (LT-2)
Holder mounting bolt: 824 - 1,030 N•m

● Adjust the backlash and tooth contact simultaneously.
i. Move the bevel gear with the adjustment nuts (28) and
(29). At this time, rotate the nuts on both sides by the same
turns in the same direction so that the preload on the bear-
30-214 HM400-1L
Apply dial gauge 1! perpendicularly to the reversing tooth

ii.
surface at the outer end of the bevel gear. Rotate the
adjustment nuts until the dial gauge indicates 0.3 - 0.4mm.
with the pinion fixed.

between differential case (64) and transfer case (17).

★ See Adjusting tooth contact in C below.
C. Adjusting tooth contact of bevel gear and bevel pinion
Testing
i. Apply red lead thinly to the tooth surfaces of the bevel

pinion and turn the bevel gear in the forward and reverse
directions, then check the tooth contact pattern on the
bevel gear.
ii.
The center of the tooth contact must be at the middle of the
tooth height and about 33% (b) of tooth depth from the
small end. The width of the tooth contact must be 30 -
60% (a) of the tooth depth. Check that there is not a strong
contact at the tips or bottoms of the teeth of both small end
and large end.
they are loaded.
HM400-1L 30-215
Adjusting
If the tooth contact pattern is not proper, adjust it according to the fol-
lowing procedure.
iii. If the bevel pinion is too far from the center line of the
bevel gear, the contact is at the small end of the bevel gear
tooth surfaces curved outward and at the large end of the
bevel gear tooth surfaces curved inward.
● In this case, adjust the tooth contact according to the fol-
lowing procedure. Adjust the thickness of the shims on the
bevel pinion side to move the bevel pinion in direction A.
Adjust the thickness of the shims of both carrier assem-
blies to move the bevel gear in direction B, then check the
tooth contact pattern and backlash again.
iv. If the bevel pinion is too close to the center line of the
bevel gear, contact is at the large end of the bevel gear
tooth faces curved outward and the small end of the bevel
gear tooth faces curved inward.
● In this case, adjust the tooth contact similarly to iii above.
★ If the shim on the either side is reduced to adjust the pro-
jection of the bevel gear, increase the shim on the opposite
side by the same quantity so that the preload on the bear-

★ 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.
30-216 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT FINAL DRIVE AND BRAKE
REMOVAL OF FRONT FINAL DRIVE

AND BRAKE
1. Draining oil from front final drive case
Drain oil from the front final drive case.
2. Jacking up
A. Jack up the front (sub) frame and support it on stand B, etc.
B. Jack up the front axle support section with jack C, etc.
3. Left fender
Lift of left fender (1).
4. Front wheels
Sling the front wheels (2) temporarily, then remove the mounting
bolts and front wheels (2).
Front wheel assembly: 800 kg (1,764 lbs)
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.
HM400-1L 30-217
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT FINAL DRIVE AND BRAKE
6. Brake cooling tubes and brake drive hose
Disconnect brake cooing tubes (4) (two pieces) and brake drive
hose (5).
7. Front final drive and brake and side drive shaft assembly
Lift off front final drive and brake and side drive shaft assembly
(6).
★ When removing, take extreme care that the spline at the
center of the side drive shaft will not come out.
Front final drive and brake and side drive shaft:

610 kg (1,345 lbs)
30-218 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FRONT FINAL DRIVE AND BRAKE
INSTALLATION OF FRONT FINAL

DRIVE AND BRAKE
Front wheel mounting bolt: 824 - 1,030 N•m
Drive shaft mounting bolt between front differential and front

final drive: Adhesive (LT-2)
Front wheel mounting bolt: 98 - 123 N•m

cuit.
Refilling with oil

● Pour the specified oil in the final drive case to the specified level.
HM400-1L 30-219
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
DISASSEMBLY OF FRONT FINAL

DRIVE AND BRAKE
1. Drive shaft (1)
Remove drive shaft (1).
★ When removing the drive shaft, take care that its cap (yoke)
will not come off.
2. Cover and shaft

Remove cover (2) and snap ring (3), then remove shaft (4) toward
the opposite side.
★ Drain the remaining oil from the case.
★ 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 difference measured on a level
place is larger than 0.3 mm, do not use it again.
30-220 HM400-1L
3. Place the assembly with the brake side down.
4. Sun gear
Remove sun gear (5).
5. Carrier assembly
A. Remove carrier assembly (6).
B. Disassemble the carrier assembly according to the following

procedure.
i. Remove shaft (7).

★ Take care not to lose ball (8).
ii. Remove planetary gear (9) and bearing (10).
HM400-1L 30-221
6. Thrust washer
Remove thrust washer (11).
7. Plate
Using forcing screw B, remove plate (12).
8. Retainer and shim
A. Using tools J1 (Install them to three places on the periphery,

equally spaced), secure inner gear (13) and outer gear (14).
★ Be sure to install tool J1 to protect the floating seal before
removing retainer (15).
★ Install tools J1 to three places on the periphery, equally
spaced.
B. Remove the mounting bolts, retainer (15), and shim.
9. Ring gear
A. Remove ring gear (16).
30-222 HM400-1L
B. Disassemble the ring gear according to the following proce-
dure.
i. Remove mounting bolts (17) and holder (18).
ii. Remove inner hub (20) from ring gear (19).
10. Floating seal cage and floating seal

Remove floating seal cage (21) [including a half part of floating
seal (22a)].
★ Use a forcing screw of M10 (long size) to remove the floating
seal cage.
HM400-1L 30-223
11. Place the assembly with the brake side up.
12. Brake assembly
A. Remove brake assembly (24) from shaft (23).

★ Make match marks in advance.
B. Disassemble the brake assembly according to the following

procedure.
i. Remove tools J1.
ii. Remove cylinder assembly (25).
iii. Disconnect the cylinder assembly according to the follow-

ing procedure.
a. Remove piston (27) from cylinder (26).
30-224 HM400-1L
b. Remove seal rings (28) and (29) from cylinder (26) and
piston (27).
C. Remove damper (end plate) (30), plate (31), and disc (32).
★ Check the cut of the plate.
HM400-1L 30-225
13. Hub (inner gear) and outer gear
A. Remove outer gear (34) from hub (inner gear) (33).
B. Remove floating seal and cage assembly (36) and floating seal
(22b) from hub (inner gear) (35).Check the cut of the plate.
C. Remove floating seal (37a) from floating seal and cage assem-
bly (36).
30-226 HM400-1L
D. Remove cover (39) from outer gear (38), then remove seal
(40).
E. Remove floating seal (37b) from outer gear (38).
14. Shaft (Tube) assembly

Remove bearing inner race (42), retainer (43), seal (44), and bush-
ing (45) from shaft (tube) (41).
HM400-1L 30-227
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF FRONT FINAL DRIVE AND BRAKE
ASSEMBLY OF FRONT FINAL DRIVE

AND BRAKE
A. Install retainer (43) to shaft (tube) (41), then install bearing

inner race (42).
B. Install bushing (45) and seal (44) to shaft (tube) (41)

★ Dimension "c" between shaft (tube) end and seal end: 29
± 0.2 mm
★ Dimension "b" between shaft (tube) mounting part and
bushing end: 5 ± 0.2 mm
A. Using tool J5, install floating seal (37o) to outer gear (38).
B. Using tool J2, install seal (40) to outer gear (38).
30-228 HM400-1L
C. Install cover (39) to outer gear (38).
D. Using tool J5, install floating seal (37a) to cage (46).

★ Measure height A of the seal above the gear, hub, and
ratainer (at four places on the periphery) and check that its
dispersion is less than 1 mm.
E. Using tool J5, install floating seal (22b) to hub (inner gear)
(35).
F. Install floating seal and cage assembly (36) to hub (internal

gear) (35).
HM400-1L 30-229
G. Install outer gear (34) to hub (inner gear) (33).
★ Take extreme care that the floating seal will not be dam-
aged or rolled up.
3. Brake assembly
A. Install disc (31), plate (30), and damper (end plate) (29).
★ When installing the plate, match the six cuts on its periph-
ery.
30-230 HM400-1L
B. Assemble the brake assembly according to the following pro-
cedure.
i. Assemble the cylinder assembly according to the follow-

ing procedure.
a. Install seal rings (28) and (29) to cylinder (26) and pis-
ton (27).
b. Install piston (27) to cylinder (26).
ii. Install cylinder assembly (25).
Cylinder mounting bolt: 157 - 196 N•m
HM400-1L 30-231
iii. Install tools J1.
C. Install brake assembly (24) to shaft (23).
A. Using tool J5, install floating seal (22a) to cage (21).

30-232 HM400-1L
B. Install floating seal cage (21) {including a half part of floating
seal (22a)}.
6. Ring gear
A. Assemble the ring gear according to the following procedure.
i. Using tool J3, press fit bearing inner race (46) to inner hub
(20).
ii. Install holder (18) and tighten mounting bolts (17).
Holder mounting bolt: 27.5 - 34 N•m
HM400-1L 30-233
B. Install ring gear (16).
A. Adjust the preload on the bearing according to the following

procedure.
i. Install retainer (15) with the bolts temporarily without

inserting any shims.
ii. Remove tools J1 (from three places) and tighten the bolts.
iii. Secure the assembly to forklift B, etc. Rotating the inner

gear (13) by 20 - 30 turns, evenly tighten every other bolt,
four in total, to 78.5 ± 4.9 Nm.
★ If the bolts are tightened without rotating the inner gear
(13), the bearing does not fit and proper preload is not
applied to it.
iv. Using depth micrometer C, measure distance "c" between

the ends of the shaft and retainer (15).
★ Measure the distance at two places and obtain the average.
v. 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.
30-234 HM400-1L
B. Set a shim of proper thickness and retainer (15) and tighten the
mounting bolts.
★ Rotating inner gear (13), tighten the mounting bolt evenly
until the tightening torque becomes constant.
Threaded parts of retainer mounting bolts:

Adhesive (LT-2)
Retainer mounting bolt: 157 - 196 N•m
★ After tightening the mounting bolts, turn inner gear (13) and
check that it rotates normally.
8. Shaft
Install shaft (4).
9. Plate
Install plate (12).
HM400-1L 30-235
10. Thrust washer
Install thrust washer (11).
11. Carrier assembly
A. Assemble the carrier assembly according to the following pro-

cedure.
i. Install bearing (10) and planetary gear (9).
ii. Install shaft (7).

B. Install carrier assembly (6).
30-236 HM400-1L
12. Sun gear
Install sun gear (5) and snap ring (3).
★ If the inside diameter of removed snap ring (3) is larger than
51.4 mm or its level difference measured on a level place is
larger than 0.3 mm, do not use it again.
13. Cover
Install cover (2).
Cover mounting bolt: 98 - 123 N•m
14. Drive shaft

Install drive shaft (1).
Threaded parts of retainer mounting bolt:

Adhesive (LT-2)
Drive shaft mounting bolt: 98 - 123 N•m
HM400-1L 30-237
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER FINAL DRIVE AND BRAKE
REMOVAL OF CENTER FINAL DRIVE

AND BRAKE
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 mount-
ing bolts to remove rear (front) wheels (1).
Rear (front) wheel assembly: 800 kg (1,764 lbs)

hose (3).
30-238 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER FINAL DRIVE AND BRAKE
Remove the center final drive cover and sun gear and drive shaft
(4).
6. Center final drive assembly

Lift off center final drive assembly (5).
Center final drive assembly: 500 kg (1,102 lbs)
HM400-1L 30-239
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER FINAL DRIVE AND BRAKE
INSTALLATION OF CENTER FINAL

DRIVE AND BRAKE
Rear wheel mounting bolt: 824 - 1,030 N•m

cuit.
Refilling with oil

30-240 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF CENTER FINAL DRIVE AND PLATE
DISASSEMBLY OF CENTER FINAL

DRIVE AND PLATE
★ The sun gear was removed when the final drive and brake assembly
was removed.
2. Carrier assembly

procedure.


★ Be sure to install tool J1 to protect the floating seal before
spaced.
HM400-1L 30-241
4. Ring gear
Remove ring gear (9).
A. Disassemble the ring gear according to the following proce-

dure.
30-242 HM400-1L
seal (15a)].
seal cage.
7. Brake assembly

HM400-1L 30-243
procedure.
i. Remove tools J1.

ing procedure.
30-244 HM400-1L
piston (20).
HM400-1L 30-245
(15b) from hub (inner gear) (28).
bly (29).
30-246 HM400-1L
(33).

Remove bearing inner race (35) and retainer (36) from shaft (tube)
(34).
HM400-1L 30-247
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CENTER FINAL DRIVE AND BRAKE
ASSEMBLY OF CENTER FINAL DRIVE

AND BRAKE
1. Shaft (tube) assembly

Install retainer (36) to shaft (tube) (34), then install bearing inner
race (35).
A. Using tool J5, install floating seal (30b) to outer gear (31).
30-248 HM400-1L
(28).

gear) (28).

aged or rolled up.
HM400-1L 30-249
3. Brake assembly
ery.

cedure.

ing procedure.
ton (20).
30-250 HM400-1L
HM400-1L 30-251
B. Install floating seal cage (14) [including a half part of floating

seal (15a)].
30-252 HM400-1L
6. Ring gear
(13).
HM400-1L 30-253

procedure.

inserting any shims.
iii. Rotating the inner gear (6) by 20 to 30 turns, evenly

tighten every other bolt, four in total, to 73.5 ± 0.98 Nm.
applied to it
iv. Using depth micrometer 1, measure distance "c" between

the ends of the shaft and retainer (8).
v. Remove retainer (8) 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.
30-254 HM400-1L
mounting bolts.

Adhesive (LT-2)
Retainer mounting bolt: 157 - 196 N•m
★ After tightening the mounting bolts, rotate inner gear (6)

and check that it rotates normally.
8. Carrier assembly

cedure.


★ Install the sun gear when installing the final drive and brake assem-
bly.
HM400-1L 30-255
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR FINAL DRIVE AND BRAKE
REMOVAL OF REAR FINAL DRIVE AND BRAKE

1. Remove the body assembly. For details, see Removal 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 remove the mounting
bolts to remove rear wheels (1).
Rear wheel assembly: 800 kg (1,764 lbs)

hose (3).
30-256 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF REAR FINAL DRIVE AND BRAKE
Remove the rear final drive cover and sun gear and drive shaft (4).
7. Center final drive and brake assembly

Lift off the center final drive and brake assembly.
Rear final drive and brake assembly:

500 kg (1,102 lbs)
INSTALLATION OF REAR FINAL

DRIVE AND BRAKE

Target: 926 N•m

cuit.
Refilling with oil

● Check the oil level in the hydraulic tank and add the specified oil to the specified level if necessary.
HM400-1L 30-257
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF REAR FINAL DRIVE AND BRAKE
DISASSEMBLY OF REAR FINAL

DRIVE AND BRAKE
★ The sun gear was removed when the final drive and brake assembly
was removed.
2. Carrier assembly

procedure.


★ Be sure to install tools J1 to protect the floating seal before
spaced.
30-258 HM400-1L
4. Ring gear
A. Remove ring gear (9).
B. Disassemble the ring gear according to the following proce-

dure.
HM400-1L 30-259
seal (15a)].
seal cage.
7. Brake assembly

30-260 HM400-1L
procedure.
i. Remove tools J1.

ing procedure.
HM400-1L 30-261
piston (20).
30-262 HM400-1L
(15b) from hub (inner gear) (28).
bly (29).
HM400-1L 30-263
(33).
9. Shaft (tube) assembly

Remove bearing inner race (35), retainer (36), seal (37), and bush-
ing (38) from shaft (tube) (34).
30-264 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF REAR FINAL DRIVE AND BRAKE
ASSEMBLY OF REAR FINAL DRIVE

AND BRAKE

Install retainer (36) to shaft (tube) (34), then install bearing inner
race (35).
A. Using tool J5, install floating seal (30b) to outer gear (31).
HM400-1L 30-265
(28).

gear) (28).

aged or rolled up.
30-266 HM400-1L
3. Brake assembly
ery.

cedure.

ing procedure.
ton (20).
HM400-1L 30-267
30-268 HM400-1L
B. Install floating seal cage (14) {including a half part of floating
seal (15a)}.
6. Ring gear
(13).
HM400-1L 30-269

procedure.

inserting any shim.
iii. Rotating the inner gear (6) by 20 to 30 turns, evenly

tighten every other bolt, four in total, to 73.5 ± 0.98 Nm.
applied to it.
30-270 HM400-1L
iv. Using depth micrometer B, measure distance "c" between

the ends of the shaft and retainer (8)
v. Remove retainer (8) 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.
mounting bolts.

Adhesive (LT-2)
★ After tightening the mounting bolts, rotate inner gear (6)

and check that it rotates normally.
8. Carrier assembly

cedure.


★ Install the sun gear when installing the final drive and
brake assembly.
HM400-1L 30-271
DISASSEMBLY AND ASSEMBLY REMOVAL OF CENTER AXLE
REMOVAL OF CENTER AXLE


assembly.
2. Jacking up frame
A. Jack up the rear frame and support it on stand B, etc.
B. Jack up the center axle and rear axle with jacks C and D.
3. Center wheels
Sling both center wheels temporarily, then remove the mounting
bolts and center wheels (1).
Center wheel assembly: 800 kg (1,764 lbs)
4. Piping and harnesses

cooling hoses (6) (three pieces), and rear retarder oil temperature
sensor connector (CN-T13) (7).
30-272 HM400-1L
Remove the guard and sling off drive shaft (8) between the center
differential and rear differential.

Remove the guard and disconnect the center differential end of
drive shaft (9) between the hitch frame and center differential and
fix it to the rear frame.
Drive shaft between hitch frame and center differential: 85

kg (187 lbs)
7. Lateral rod
Remove lateral rod (10).
Lateral rod: 60 kg (132 lbs)
8. Equalizer bar spring

Remove equalizer bar spring (11).
9. Center axle and arm assembly
A. Sling center axle and arm assembly (12) temporarily.
HM400-1L 30-273
B. Remove holder plate (13) of the center axle arm support, then
remove center axle and arm assembly (12) down.
Center axle and arm assembly: 2,200 kg (4,850 lbs)
30-274 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER AXLE
INSTALLATION OF CENTER AXLE

Center wheel mounting bolt: 824 - 1,030 N•m

Target: 113 N•m
★ When installing the lateral rod, match tap hole (a) to the center line
of bearing (15) as shown in Fig. 1.
HM400-1L 30-275
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CENTER AXLE
★ Install the center axle and arm assembly so that distance (y)
between the rear frame top and equalizer bar spring top will be 201
mm when distance (x) between the rear suspension cylinder pins is
574 mm (Clearance "z" between the rear axle top and rear frame
bottom is 130 mm at this time).

cuit.
★ Adjust the suspension cylinder length. For details, see TESTING

AND ADJUSTING, Testing and adjusting suspension cylinder.
Refilling with oil

30-276 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR AXLE
REMOVAL OF REAR AXLE


assembly.
2. Jacking up frame
A. Jack up the rear frame and support it on stand B, etc.
B. Jack up the center axle and rear axle with jacks C and D.
3. Rear wheels
Sling both rear wheels temporarily, then remove the mounting bolts
and rear wheels (1).
4. Piping and harnesses

cooling hoses (6) (two pieces), and rear brake oil temperature sen-
sor connector (CN-T13) (7).
HM400-1L 30-277
Remove the guard and sling off drive shaft (8) between the center
differential and rear differential.
6. Lateral rod
Remove lateral rod (9).
7. Bracket (left)
Remove bracket (left) (10).
8. Rear axle and arm assembly
A. Sling rear axle and arm assembly (11) temporarily.
30-278 HM400-1L
B. Remove holder plate (12) of the rear axle arm support pin.
C. Pull out lower pin (14) of rear suspension cylinder (13) and
remove rear axle and arm assembly (11) down.
Rear axle and arm assembly: 2,200 kg (4,850 lbs)
HM400-1L 30-279
DISASSEMBLY AND ASSEMBLY INSTALLATION OF REAR AXLE
INSTALLATION OF REAR AXLE


Target: 926 N•m

Target: 113 N•m
★ Install the rear axle and arm assembly so that distance (y) between
the rear frame top and equalizer bar spring top will be 201 mm
when distance (x) between the rear suspension cylinder pins is 574
mm (Clearance "z" between the rear axle top and rear frame bottom
is 130 mm at this time).

cuit.

Refilling with oil

30-280 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT SUSPENSION CYLINDER
REMOVAL OF FRONT SUSPENSION CYLINDER

★ Release nitrogen gas from the front suspension cylinder. For
details, see TESTING AND ADJUSTING, Testing and adjusting
suspension cylinder.
1. Jacking up
2. Left fender
Lift left fender (1).
3. Front wheels
HM400-1L 30-281
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FRONT SUSPENSION CYLINDER
4. Front suspension cylinder
A. Remove the cover and disconnect grease tube (3).
B. Remove upper and lower pins (4) and (5) and front suspension
cylinder assembly (6).
INSTALLATION OF FRONT SUSPEN-

SION CYLINDER
● Carry out installation in the reverse order to removal.

Target: 926 N•m

30-282 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR SUSPENSION CYLINDER
REMOVAL OF REAR SUSPENSION CYLINDER

★ Release nitrogen gas from the rear suspension cylinder. For details,
see TESTING AND ADJUSTING, Testing and adjusting suspen-
sion cylinder.
1. Jacking up and lateral rod
A. Jack up the rear frame and rear axle with jacks B and C.
B. Lower lateral rod (1) and pull it out toward you.
WARNING! Since the lateral rod cannot be slung,

secure it (with a rope, etc.) and remove it,
watching your steps carefully.
2. Bracket
Remove bracket (2).
3. Rear suspension cylinder

Using balancing rod (3), etc., remove upper and lower pins (3) and
(4) and rear suspension cylinder assembly (5).
HM400-1L 30-283
DISASSEMBLY AND ASSEMBLY REMOVAL OF REAR SUSPENSION CYLINDER
INSTALLATION OF REAR SUSPENSION CYLINDER


30-284 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF EQUALIZER BAR
REMOVAL OF EQUALIZER BAR
WARNING! Stop the engine and operate the hoist cyl-

inder control lever two to three times to
release the remaining pressure.
WARNING! Loosen the oil filler cap to release the

remaining pressure from the hydraulic
tank.
1. Release the nitrogen gas.

● Release nitrogen gas from the rear suspension cylinder. For
details, see TESTING AND ADJUSTING, Testing and adjust-
ing suspension cylinder.

assembly.
3. Remove the hoist cylinder.
A. Disconnect hoses (1) and (2)

★ Plug the hoses to prevent the oil from flowing out.
B. Sling the hoist cylinder temporarily and bring it down at a right

angle to vehicle body.
WARNING! Pull the hoist cylinder toward inside of the

vehicle body in advance. (If the rod pin is
removed, the hoist cylinder falls. Accord-
ingly, be sure to pull the cylinder toward
inside of the vehicle body in advance.)
C. Remove rod pin (3) and hoist cylinder (4).
Hoist cylinder: 270 kg (595 lbs)
4. Remove the rear wheels (front and rear) on the side from which the
equalizer bar will be removed. For details, see Removal of rear
wheel assembly.
5. Remove bottom pin (5) of the rear suspension cylinder and bring
cylinder (6) down toward the rear of the vehicle body.
HM400-1L 30-285
DISASSEMBLY AND ASSEMBLY REMOVAL OF EQUALIZER BAR
6. Remove four mounting bolts (8) of the equalizer bar above cushion
(7).
7. Sling the equalizer bar temporarily.
8. Remove mounting bolts (10) of plate (9) at the center of the equal-
izer bar.
9. Using forcing screw B, remove bushing (11).
10. Lift off equalizer bar (12).
Equalizer bar: 250 kg (551 lbs)
30-286 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF EQUALIZER BAR
INSTALLATION OF EQUALIZER BAR

Refill the rear suspension cylinder with nitrogen gas. For details, see
Testing and adjusting suspension cylinder.
Rod pin: 157 - 196 N•m
★ When installing the plate, measure the distance between the vehicle
body and equalizer bar and adjust the difference between distances
"a" and "b" and between "c" and "d" will be 2 mm respectively.
Plate (Diameter of thread: 24mm): 824 - 1,030 N•m

(Diameter of thread: 14mm): 157 - 196 N•m
★ Install the rear axle and arm assembly so that distance (y) between
the rear frame top and equalizer bar spring top will be 201 mm
when distance (x) between the rear suspension cylinder pins is 574
mm (clearance "z" between the rear axle top and rear frame bottom
is 130 mm at this time).
Refilling with oil

★ Pour the specified oil in the final drive case to the specified level.
★ Add engine oil (EO10-CD) to specified.
HM400-1L 30-287
DISASSEMBLY AND ASSEMBLY REMOVAL OF FRONT WHEEL
REMOVAL OF FRONT WHEEL

1. Jacking up
2. Left fender
Lift of left fender (1).
3. Front wheels
INSTALLATION OF FRONT WHEEL

Carry out installation in the reverse order of removal.

Target: 926 N•m
30-288 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR WHEEL AS-
REMOVAL AND INSTALLATION OF

REAR WHEEL ASSEMBLY
Removal of rear (front) wheel assembly
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 mount-
ing bolts to remove rear (front) wheels (1).
Rear (front) wheel assembly: 800 kg (1,764 lbs)
Installation of rear (front) wheel assembly
Rear (front) wheel mounting bolt: 824 - 1,030 N•m

Target: 926 N•m
Removal of rear (rear) wheel assembly

assembly.
★ If the rear (rear) wheel assembly is removed with a forklift,
etc., step 1 above is not necessary.
2. Jacking up rear axle

Jack up the rear axle.
3. Rear (rear) wheel

Sling rear wheels (1) temporarily and remove the mounting bolts to
remove rear wheels (1).
Installation of rear (front) wheel assembly
Installation of rear (rear) wheel assembly
Rear (rear) wheel mounting bolt: 824 - 1,030 N•m

Target: 926 N•m
HM400-1L 30-289
DISASSEMBLY AND ASSEMBLY REMOVAL OF HITCH FRAME
REMOVAL OF HITCH FRAME


safety pin.
1. Piping, hoses, and wiring harnesses
A. Disconnect hoist cylinder hoses (1) and (2), brake hoses (3) -
(6), brake cooling hoses (7) and (8), and parking brake hose
(9).
B. Disconnect joint connectors (CN-J015) (10) and (CN-J013)

(11) and differential lock connector (CN-B36).
2. Parking brake assembly
A. Release the parking brake.
B. Remove pad expansion spring bracket (12).
C. Remove the mounting bolts of plate (13) and parking brake and
cylinder assembly (14).
30-290 HM400-1L
Remove the guard and drive shaft (15) between the hitch frame and
center differential.
Drive shaft between hitch frame and center differential:

85 kg (187 lbs)
4. Parking brake disc and coupling assembly

Remove the coupling holder, then remove parking brake disc and
coupling assembly (16).
Parking brake and coupling assembly: 55 kg (121 lbs)
5. Parking brake bracket.

Remove parking brake bracket (17).
Parking brake bracket: 55 kg (121 lbs)
6. Drive shaft between transmission and hitch frame

Remove the guard and disconnect the transmission end of drive
shaft (18) between the transmission and hitch frame.
Drive shaft between transmission and hitch frame:

55 kg (121 lbs)
HM400-1L 30-291
7. Steering cylinder
Remove head pin (19) and disconnect steering cylinders (20) (on
both sides).
8. Jacking up vehicle body
A. [Front operator’s cab side]
i. Sling the front part with a crane [chain B].
ii. Place a stand under the rear frame for safety.
B. [Rear dump body side]
i. Support the rear dump body end on block C.
ii. Support the front frame with a jack, etc. for safety.
9. Hinge pins
A. Move the rear frame of the front operator’s cab section and the
front frame of the rear dump body section up and down with
jacks D and E to center the hinge pins.
30-292 HM400-1L
B. Remove plate (21) and pull down out upper hinge pin (22).
C. Pull up out lower hinge pin (23) with a jack.
HM400-1L 30-293
10. Disconnection of front and rear sections
Hold the front part of the front operator’s cab section with a forklift
and a crane and move it forward to disconnect from the rear dump
body section.
WARNING! Keep the level of the front and rear parts

around the pins until the rear frame of the
front operator’s cab section is separated
from the hitch frame.
WARNING! Check that there are clearances "a" and

"b" between the rear frame of the front
operator’s cab section and the hitch
frame, then disconnect the front opera-
tor’s cab section from the rear dump body.
WARNING! Move the rear frame of the front opera-

tor’s cab section 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.
11. Hitch frame assembly
A. Remove rear seal and retainer (large) assembly (24).
B. Using forcing screw F, remove end retainer (25).
30-294 HM400-1L
C. Pulling out hitch frame assembly (26) forward, lift it off.
★ When pulling out the hitch frame assembly forward, hold
bearing inner race (26i) so that it will not fall.
★ Push out the side end of hitch frame (25) forward with a
thin and small puller, and the hitch frame is pulled out
(removed) easily.
★ After pulling out the hitch frame halfway, increase the
number of slings (change the slinging position) so that the
hitch frame will be balanced when lifted off.
HM400-1L 30-295
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HITCH FRAME
INSTALLATION OF HITCH FRAME

● Carry out installation in the reverse order of removal
★ Bleed air from the brake circuit. For details, see TESTING
AND ADJUSTING, Bleeding air from brake circuit.
★ Test the wear of the brake pad and adjust the brake pad clear-
ance. For details, see TESTING AND ADJUSTING, Testing
wear of parking brake pad.
★ When installing the drive shaft, check that the key way of the
spider cap is matched to that of the mating yoke and tighten the
bolts.
Mounting bolt of drive shaft between hitch frame and center

differential: Adhesive (LT-2)
Mounting bolt of drive shaft between hitch frame and

center differential:157 - 198 N•m
Target:177 N•m
Coupling spline: LM-P
Coupling bolt: Adhesive (LT-2)
Coupling bolt: 824 - 1,030 N•m
Mounting bolt of drive shaft between transmission and hitch

frame: Adhesive (LT-2)
Mounting bolt of drive shaft between transmission and

hitch frame: 157 - 198 N•m
Target: 177 N•m
30-296 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HITCH FRAME
★ When installing rear seal (27) to rear retainer (28), use push tool
G matched to the diameter of the seal.
★ Procedure for adjusting bearing of oscillation section
A. Measure thickness "t" of end retainer (25) at two places

(equally spaced on the periphery).
B. Tighten mounting bolts (30) (three pieces) to the following

torque without inserting shim (29).
Mounting bolt: 68.6 N•m (Target)
C. Under this condition, measure dimension "d" with a microme-

ter.
D. Rotate hitch frame (31) by five to six turns, then repeat steps B
and C above.
★ Repeat steps B through D above until dimension "d" is sta-
bilized.
E. Combine shims so that difference "e" of the measured values (e

= d - 5) will be 0 - 0.15 mm.
F. After finishing the above adjustment, tighten all mounting

bolts (30) to the following torque.
Mounting bolt: 385 N•m (Target)
HM400-1L 30-297
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HITCH FRAME
DISASSEMBLY OF HITCH FRAME

1. Coupling
Remove coupling holder (1) and coupling (2).
2. Rear retainer
A. Using forcing screw B, remove retainer assembly (3).
B. Remove ring (5) and dust seal (6) from rear retainer (4).
3. Center shaft
A. Remove center shaft and bearing assembly (8) from hitch

frame (7).
30-298 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HITCH FRAME
B. Remove rear bearing (10) and front bearing inner race (11i)
from center shaft (9).
4. Disassembly of hitch frame
A. Remove front cage assembly (13), ring (14), front bearing

outer race (11o), and rings (15) and (16) from hitch frame (12).
B. Remove dust seal (18) from front cage (17).
HM400-1L 30-299
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HITCH FRAME
ASSEMBLY OF HITCH FRAME

★ When installing a seal, use a push tool matched to the diameter of
that seal, even if use of the push tool is not described in this manual.
1. Center shaft
Using the push tool, press fit rear bearing (10) and bearing inner
race (11i) to center shaft (9).
2. Assembly of hitch frame

Install ring (15) and front bearing outer race (11o) to the front side
of hitch frame (12). Install ring (16) to the rear side of the hitch
frame (12).
Fill the inside space of ring (15) with grease [Part A: 60%
pack (76g), Part: 60% pack (88g)].
Fill the inside space of front bearing outer race (11o) with
grease [Part 1: 40% pack (27g)].
Fill the inside space of rear bearing (10) with grease [Part J:
40% pack (23g)].
★ Select grease for the above parts from Table 1.

Table 1
No Manufacturer Grease brand

1 Nippon Oil Hirex
2 Shell Oil Super Duty Grease 2
3 Esso Oil RONEX MP
4 BP Energrease LS-EP2
30-300 HM400-1L
3. Installation of center shaft and bearing assembly
Install the center shaft and bearing assembly (8) to hitch frame (7)
carefully from rear.
★ At this time, press fit rear bearing (10) to hitch frame (7), too.
Fill the inside space of rear bearing (10) with grease [Part J:
40% pack (23g)].
★ Select grease for the above parts from Table 1. (For part J, see
2 above.)
Table 1

1 Nippon Oil Hirex
3 Esso Oil RONEX MP
4. Ring and front cage assembly
A. Install ring (14) to hitch frame (12).
B. Install dust seal (18) and O-ring to front cage (17), then install
front cage (13) to hitch frame (12).
Apply grease to the lip of dust seal (18).
Fill the inside space of dust seal (18) with grease [Part K: Full
pack (25g), Part C: 60% pack (74g)].
★ Select grease for the above parts from Table 1.

Table 1

1 Nippon Oil Hirex
3 Esso Oil RONEX MP
HM400-1L 30-301
5. Coupling
Install coupling (2) and coupling holder (1).
Coupling spline: LM-P
Coupling bolt: 824 - 1,030 N•m
6. Rear retainer
A. Install ring (5), dust seal (6), and O-ring to rear retainer (4).
B. Install rear retainer assembly (3).
30-302 HM400-1L
DISASSEMBLY AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
STANDARD INTEGRAL ORBIT-ROLL
Tools needed for disassembly and assembly

(1) Torque wrench (torque capacity: 5kgfm) (7) Plastic hammer
(2) 5/12 in - 12 point socket (8) Small amount of grease
(3) Flat-headed screwdriver (large) (9) Vice
(4) Flat-headed screwdriver (small) (10) Oil-based felt pen
(5) Spring insertion tool (P/N 600057) (11) Tweezers
(6) 3/16 in hexagonal wrench
HM400-1L 30-303
DISASSEMBLY AND ASSEMBLY STANDARD INTEGRAL ORBIT-ROLL
Part No. Part name Qty 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
30-304 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING VALVE
DISASSEMBLY OF STEERING VALVE

★ When disassembling the valve, cleanliness is extremely important.
Work in a clean place.
★ In the following explanation diagrams, it is not absolutely neces-
sary to hold the unit in a vice, but it is recommended to use a vice as
much as possible.
★ Before removing the piping, remove all dirt and dust from around
the ports and joints on the outside circumferences of the motor.
WARNING! 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 housing between copper
sheets in vice I, and be careful not to over-tighten vice.
2. Remove six screws (1) and one retainer screw (2), then remove end
cap (3). Remove O-ring (22) from end cap (3).
3. Remove spacer (5) inside spline on inside of star of Gerotor (4).

Remove Gerotor (4). Be careful not to drop star from ring of outer
circumference of Gerotor.
Remove O-ring (22) from Gerotor.
HM400-1L 30-305
4. Remove drive (8), then remove spacer plate (7). Remove O-ring
(23) from housing.
5. Using flat-headed screwdriver, remove adapter screw (39). Remove

housing from vice, set upside down, then remove ball (40).
★ Be careful not to drop or lose the ball.
6. Set housing upside down, remove two springs (31), two retainer
lugs (30), and two balls (32).
★ Be careful not to drop or lose the parts.
7. Set on clean cloth with flange surface of housing facing up to pre-

vent damage to finished surface. Use a flat-head screwdriver to
raise tip of retaining ring (20), then remove from housing.
WARNING! The retaining ring may fly out from the

housing, so always wear protective
glasses.
30-306 HM400-1L
8. Set housing on clean cloth with axial line of valve horizontal. Turn
spool and sleeve assembly to set sleeve pin in horizontal position,
then push out spool and sleeve assembly slightly, and remove seal
gland bushing (21) from housing.
Remove oil seal and dust seal from gland bushing.
★ When removing the seal, be careful not to damage the seal
gland bushing.
9. Remove two race bearings (15) and thrust needle (16).
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 housing.
★ Depending on the assembly of sleeve and spool, it may not
work properly if it is assembled 180° from the proper direction,
so make marks to show the position of spool and sleeve (43).
Remove pin (12).

glasses.
11. Push out spool inside sleeve slightly, and remove centering spring
(13) carefully by hand from spool.
HM400-1L 30-307
12. Rotate spool slowly and pull out spool (11) from sleeve (10).
Remove O-ring from housing.
DISASSEMBLY OF STEERING RELIEF VALVE
● Using hexagonal wrench (width across flats: 3/16 inch),

remove plug (28). Remove O-ring (29) from plug. Using twee-
zers, remove spring (27) and poppet (26).
★ The valve seat is stuck to the housing and cannot be removed.
DISASSEMBLY OF OVERLORD RELIEF VALVE
● Using hexagonal wrench (width across flats: 3/16 inch),

remove plug (37) (two places). Remove O-ring (38) from plug.
Using tweezers, remove two springs (36), two ball holders
(35), and two balls (34).
★ The valve seat is stuck to the housing and cannot be removed.
30-308 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING VALVE
ASSEMBLY OF STEERING VALVE

● Check all the joining parts.
Parts with gouges or burrs will cause oil leakage, 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.
WARNING! Be extremely careful not to injure yourself

on the edges of sleeves, spools, housing,
and other machined parts.
● As a basic rule, assemble new O-rings and seal after disassem-

bling. Coat the O-rings with a small amount of clean grease
before assembling.
● The O-rings in front of or behind the spacer plate are of very
similar sizes, so check the part number before opening the seal
kit, and be extremely careful not to mix them.
1. Turn spool (11) and insert slowly into sleeve (10). Grip spline por-
tion of spool and check that spool rotates smoothly inside sleeve.
Align mark made when disassembling.
2. Align two spring grooves at 180° in spool and sleeve, then stand on
a horizontal plate. Insert spring insertion tool (Part No.: 60057) 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 cen-
tering 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 diameter of sleeve. Insert sleeve pin into hole in
sleeve, and align both ends of pin with outside diameter of sleeve.
WARNING! The centering spring may fly out from the

spool, so always wear protective glasses.
HM400-1L 30-309
3. Set housing on clean cloth with axial line of valve horizontal. Insert
spool and sleeve assembly from opposite end of housing to flange
end. In this condition, check that spool and sleeve assembly rotates
smoothly inside housing.
★ When inserting spool and sleeve assembly, be careful not to
insert it at an angle and get it caught. Keep the pin at near the
horizontal position, and rotate slightly to left and right to insert.
★ Insert so that the end face of the spool 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.
4. Place housing on clean flat surface, then assemble O-ring (17).

Assemble two race bearings (15) and thrust needle (16). Always
insert thrust needle between race bearings.
★ There are two types of seal: Teflon seal and standard seal.
5. Assemble dust seal (19) to seal gland bushing (21). Assemble dust
seal so that flat surface is at seal gland bushing end. Assemble oil
seal (18) to seal gland bushing.
★ Assemble the oil seal carefully so that there is no twisting or
deformation.
★ The diagram below is the Teflon seal specification drawing;
(44) is the distinguishing groove.
★ The diagram below is the standard seal specification drawing.
30-310 HM400-1L
6. After assembling seals, rotate seal gland bushing (21) and insert to
spool. Tap with plastic hammer to insert to specified position.
Assemble retaining ring (20) to housing.
★ Push open with a flat-headed screwdriver so that the whole cir-
cumference of the retaining ring fits securely in the groove in
the housing.

glasses.
★ Seal assembly drawing

Screwdriver J, dust seal (19), retaining ring (20), seal gland
bushing (21), oil seal (18), O-ring (17).
ASSEMBLY OF STEERING RELIEF VALVE
● Assemble O-ring (29) to plug (28).

Using tweezers, assemble spring (27) and poppet (26) to housing.
Using hexagonal wrench (width across flats: 3/16 inch), assemble
plug (28) to housing.
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.
★ The size of the overload valve ball and the anti-cavitation
check valve ball is different, so be careful not to mix them.
HM400-1L 30-311
ASSEMBLY OF ANTI-CAVITATION CHECK VALVE
● Grip the port surface and side surface of the housing lightly in a
vice. Fit copper sheets in the vice, and be careful not to tighten the
vice too strongly.
Of the seven bolt holes in the end face of the housing, insert one
each of spring (31), retainer plug (30), and ball (32) in the two holes
shown in the drawing.
★ Be careful not to drop or lose the ball. Be careful of the assem-
bly direction of the retainer plug.
ASSEMBLY OF GEROTOR END
● Grip the port surface and side surface of the housing lightly in a
vice. (45): 25 mm. Fit copper sheets in the vice, and be careful not
to overtighten the vice.
● Of the seven bolt holes in the end face of the housing, insert ball
(40) in the holes shown in the drawing. Assemble adapter screw
(39) in holes in same drawing.
● Assemble O-ring (23) to housing.

Set spacer plate (7) on top and align position of bolt holes.
★ The pitch diameter of the bolt holes and oil holes is different.
30-312 HM400-1L
● Turn spool and sleeve assembly and set pin (12) and port surface
(46) of housing in parallel. Insert drive (8) into portion (47), then
mate drive yoke and pin (12). To carry out positioning exactly, use a
felt pen to draw line on end face of drive (8) parallel to pin.
● Assemble O-ring (22) to Gerotor (4).
● Set O-ring at end face of Gerotor (4) at spacer plate (7) side, align
concave portions (48) of Gerotor star teeth with pin (12), align with
mark drawn on end face of drive (8), and assemble.
When doing this, check carefully that lines A, B, C, and D are par-
allel as shown in diagram below.
★ Turn Gerotor ring to align bolt holes. Do not remove mating of
drive and Gerotor star.
★ The above procedure is important for aligning the valve tim-
ing.
● Assemble spacer (5) to spline Gerotor star.

★ Do not assemble spacers to 51 cc/rev and 69 cc/rev discharge
capacity Orbit-rolls.
Assemble two 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 six screws (1) and thread of retainer
screw assembly (2) with oil, then assemble to end cap.
Install retainer screw assemblies to bolt holes where adapter
screws have already been assembled. 14.7 N, then tighten in
order to following torque.
HM400-1L 30-313
● Order for tightening end cap mounting screws is as shown in dia-
gram below.
★ After tightening to torque given below, install handle to spool

and check that spool rotates.
Screw tightening torque
Discharge capacity Tightening torque

cc/rev (N.m{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 thickness
capacity
capacity symbol (mm)
(cc/rev)
A 51
B 69
C 96 3.6
D 120 6.1
E 159 12.2
G 184 12.2
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
30-314 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF FLOW AMPLIFIER VALVE
REMOVAL OF FLOW AMPLIFIER VALVE

1. Tilting up operator’s cab
Bring the hood down forward (and fix it) and tilt up operator’s cab
WARNING! Check that the operator’s cab is sup-

2. Steering valve
A. Remove left side cover (2) of the operator’s cab and steering
valve side cover.
B. Remove the wire harness clamp and disconnect the steering

hose and R, P, T, L, and LS circuit hoses (3) - (6).
C. 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.
★ Loosen the mounting bolts of port P of the hoist valve.
HM400-1L 30-315
DISASSEMBLY AND ASSEMBLY INSTALLATION OF FLOW AMPLIFIER VALVE
D. Disconnect pump circuit (HP) hose (8) and remove tank circuit
(HT) piping (9).
E. Disconnect steering cylinder circuit pipes (CL) (10) and (CR)

(11) and keep them away from the steering valve.
F. Remove steering valve (12).
Steering valve: 35 kg (77 lbs)
INSTALLATION OF FLOW AMPLIFIER

VALVE
● Installing in the reverse order of removal.
30-316 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF HOIST VALVE
REMOVAL OF HOIST VALVE

1. Drain the hydraulic oil.
2. Left fender
Lift off left fender (1).
3. Steering valve
Remove the steering valve assembly. For details, see Removal of
steering valve assembly.
4. Hose and piping
A. Remove the tube of port P of the loosened hoist valve and dis-
connect tank circuit hoses (2), (3), (4).
B. Remove bracket (5) and tank circuit tube (6).
C. Remove the throttle between tube (6) and hoist valve, too.
D. Disconnect hoses (7) and (8) of pilot ports (PA) and (PB).
E. Remove check valve (9).
F. Disconnect tube (10) and (11) of hoist cylinder ports (A) and
(B).
★ Loosen the rear tube clamp and move the tubes toward the
hydraulic tank.
HM400-1L 30-317
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HOIST VALVE
5. Hoist valve
Remove hoist valve assembly (12).
Hoist valve assembly: 65 kg (143 lbs)
INSTALLATION OF HOIST VALVE

Front wheel mounting bolt: 14.7 - 34.3 N•m

Target: 24.5 N•m
Refilling with oil

● Add specified oil to the specified level.
30-318 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HOIST VALVE
DISASSEMBLY OF HOIST VALVE
1. Housing assembly 3. Body assembly

A. Remove housing (2) from body (1). A. Remove spool (27) and plug (28) from
B. Loosen nut (3). body (1).
C. Remove screw (4), nut (5), retainer (6), spring (7) and poppet B. Remove seat (29), spring (30), and valve
(8). (31) from body (1).
D. Remove holder (9) and seat (10).
E. Loosen sleeve (11) and remove spring (12), valve (13), and
retainer (14).
2. Spring case assembly

A. Remove spring case (15) from body (1), then remove springs
(16) and (17) and retainer (18).
B. Remove spring case (19) from body (1), then remove retainer
(20).
C. Remove plug (21).
D. Remove flange (22) from spring case (19), then remove springs
(23) and (24), retainer (25), and spring (26).
HM400-1L 30-319
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST VALVE
ASSEMBLY OF HOIST VALVE
● Clean the all parts carefully and remove burrs. 3. Housing assembly
● Apply engine oil to the sliding parts before installing. A. Install retainer (14), valve (13), and spring
(12) to housing (2) and tighten sleeve (11).
1. Body assembly B. Install seat (10) and holder (9) and tighten
A. Install valve (31), spring (30), and seat (29) to body (1). nut (3).
B. Install plug (28) and spool (27) to body (1). C. Install poppet (8), spring (7), and retainer
(6) and tighten nut (5) and screw (4).
2. Spring case assembly D. Install body (1) to housing (2).
A. Install spring (26), retainer (25), and springs (24) and (23) to
spring case (19), then install flange (22).
B. Install plug (21).
C. Install retainer (20) to body (1), then install spring case (19).
D. Install retainer (18) and springs (17) and (16) to body (1), then
install spring case (15).
30-320 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST VALVE
Mating faces of housing and body: Sealant (LOCTITE

#752 or 575 or Loctite #242)
Housing (Diameter of thread: 12mm): 110.3 ± 12.6

N•m
(Diameter of thread: 14mm): 176.5 ± 29.6 N•m
HM400-1L 30-321
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING CYLINDER
DISASSEMBLY OF STEERING CYLIN-

DER
1. Set cylinder assembly (1) in tool U1.
2. Raise lock of cylinder head nut, and using tool U2, remove cylinder
head assembly (2).
3. Pull out cylinder head and piston rod assembly (3) from cylinder
(4) and remove.
★ When the piston rod assembly is pulled out from the cylinder,
oil will come out, so catch it in a container.
4. Remove cylinder (4) from tool U1.
5. Disassembly of piston rod assembly
A. Set piston rod assembly (3) in tool U1.
B. Using tool U3, remove nut (5).
C. Remove piston assembly (6) and cylinder head assembly (7)

from rod (8).
30-322 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF STEERING CYLINDER
6. Disassembly of piston assembly
A. Remove wear ring (9) from piston (10).
B. Remove wear ring (11) from piston (10).
7. Disassembly of cylinder head assembly
A. Remove snap ring (12), then remove dust seal (13).
B. Remove rod packing (14).
C. Remove bushing (15) from cylinder head (16)
D. Remove O-ring (17) and backup ring (18).
HM400-1L 30-323
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF STEERING CYLINDER ASSEMBLY
ASSEMBLY OF STEERING CYLIN-

DER ASSEMBLY
● Clean all parts, and check for dirt or damage. Coat the sliding sur-
faces of all parts with engine oil before installing.
1. Assembly of cylinder head assembly
A. Using tool U5, press fit bushing (15) to cylinder head (16).
★ Take care not to deform bushing (15) when press fitting it.
B. Install rod packing (14).

★ Take care of installing direction.
C. Install backup ring (18) and O-ring (17) in order

★ Do not insert the backup ring forcibly, but heat it in water
at about 50 - 60°C, then insert it.
D. Using tool U6, install dust seal (13) to cylinder head (16).
E. Install snap ring (12).
30-324 HM400-1L
2. Assembly piston assembly
A. Using tool U4, expand piston ring (11).

★ Set piston ring (11) to the tool and rotate the handle by
eight to ten turns to expand the ring.
B. Remove piston rod (11) from tool U4 and install it to piston

(10).
C. Using tool U4, shrink the piston ring.
D. Install wear ring (9).
3. Assembly of piston rod assembly
A. Assemble cylinder head assembly (7) and piston assembly (6)

to piston rod (8).
HM400-1L 30-325
B. Using tool U4, tighten nuts (5).
Nut: Thread tightener (LT-2)
Nut: 3.97 ± 0.4 kN•m
C. Remove piston rod assembly (3) from tool U1.
4. Set cylinder (4) in toll U1.
5. Assemble cylinder head and piston rod assembly (3) in cylinder (4).
6. Using tool U2, tighten cylinder head assembly (2).
Cylinder head nut: 981 ± 98 N•m
30-326 HM400-1L
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HOIST CYLINDER ASSEMBLY
DISASSEMBLY OF HOIST CYLINDER

ASSEMBLY
● Be careful not to damage the rod packing, dust seal, piston ring, and
wear ring.
1. Set cylinder assembly to tool U1.
2. Using tool U2, remove crown (1) from cylinder I (2).

★ After loosening the crown, remove the grease nipple from the
rod head, then pull put the crown..
3. Remove cylinder II and rod assembly from cylinder I (2).
4. Remove bolt (3), then lift off rod (5) from cylinder II (4).
5. Remove cylinder head assembly (6) from cylinder II (4).
6. Remove wear ring (7) and collar (8).
HM400-1L 30-327
DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF HOIST CYLINDER ASSEMBLY
7. Disassembly of cylinder head assembly.
A. Remove O-ring, then remove dust seal (9) and rod packing
(10).
B. Remove bushing (11).
8. Remove snap ring (12) from cylinder II (4), then remove piston
assembly (13).
9. Disassembly of piston assembly

Remove piston ring (14) and wear ring (15) from piston assembly.
10. Remove snap ring (16) from cylinder II (4), then remove dust seal
(17), rod packing (18), and bushing (19).
30-328 HM400-1L
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF HOIST CYLINDER
ASSEMBLY OF HOIST CYLINDER

● Clean all parts, and check for dirt or damage. Coat the sliding sur-
faces of all parts with engine oil before installing.
1. Using tool U5, press fit bushing (19) to cylinder II (4).
2. Install rod packing (18).

★ Check the direction of assembly for the rod packing when
installing.
3. Using tool U6 fit dust seal (17) and install snap ring (16).
HM400-1L 30-329
4. Assembly of piston assembly
A. Using tool U4, expand piston ring (14), and assemble to piston
(13).
★ Set the piston ring on tool, and turn the handle eight to ten
times to expand the ring.
B. Set tools U4 in position, and compress piston ring (14).
C. Install wear ring (14)
5. Assembly piston assembly (13) to cylinder II (4), and install snap

(12).
6. Install wear ring (7) to cylinder II (4).
30-330 HM400-1L
7. Assembly of cylinder head assembly.
A. Using tool U5, press fit bushing (11).
B. Assemble rod packing (10) to cylinder head (6).

★ Check the direction of assembly for the rod packing when
installing.
C. Using tool U6 install dust seal (9).
8. Assemble cylinder head (6) to cylinder II (4).
HM400-1L 30-331
9. Sling rod (5) and assemble to cylinder II (4).
★ Align the stud bolt at the tip of the rod with the bolt hole in the
piston assembly.
10. Tighten mounting nut (3) of piston assembly.
Mounting bolt: Thread tightener (Loctite #262)
★ Remove all oil and grease from the assembly portion of the
nuts and blots.
11. Assemble cylinder II and rod assembly to cylinder I (2).
12. Using tool U2 install crown (1) to cylinder I (2), and fit grease nip-
ple.
Crown: 1,270 - 130 N•m
30-332 HM400-1L
DISASSEMBLY AND ASSEMBLY REMOVAL OF BODY ASSEMBLY
REMOVAL OF BODY ASSEMBLY

1. Remove both hoist cylinder rod pins (1).
★ Sling the bottom of the hoist cylinder temporarily.

★ After removing pin (1) from each cylinder rod, install lever
block 1 between the vehicle body and hoist cylinder and tense
it to prevent the hoist cylinder from falling down.
WARNING! If rod pin (1) is removed, the hoist cylinder

falls outward. Accordingly, be sure to pull
the cylinder toward inside of the vehicle
body in advance.
2. Loosening lever block B, lower the crane to place the bottom of the
hoist cylinder on the tire.
A. Place block C between the bottom of the hoist cylinder and

tire.
B. Install lever block B between the vehicle body and hoist cylin-
der and tense it to prevent the hoist cylinder from falling down.
3. Sling the body temporarily.
4. Disconnect body potentiometer linkage (2) from the body.
5. Remove body hinge pins (3) on both sides.
HM400-1L 30-333
DISASSEMBLY AND ASSEMBLY REMOVAL OF BODY ASSEMBLY
6. Lift off body assembly (4).
Body assembly: 4450 kg (9,811 lbs)
30-334 HM400-1L
DISASSEMBLY AND ASSEMBLY INSTALLATION OF BODY ASSEMBLY
INSTALLATION OF BODY ASSEMBLY

WARNING! Aligning the pin holes slowly with the

engine at low speed. Never insert your
fingers in the pin holes.
Bottom pin (Diameter of thread: 14mm): 157 - 196 N•m
● When installing the body hinge pin, check the thickness and quan-
tity of the shims.
Body hinge pin: 157 - 196 N•m
● Adjustment of body mount shims
A. Install spacer (5) 58 mm high to the end of body (4) (one place
on each side).
B. Measure clearance "a" between the center of the mounting part

of bottom mount (6) and frame top (7).
★ Measure at A, B, and C on both side, six places in total.
C. Calculate the thickness of the shims to be installed to each part.

★ Thickness of shims = (a - 26) mm
D. Insert shims of the calculated thickness.

★ Standard thickness of shims: 4 mm
E. Lower the body and check that all of the six parts of the bottom
mount are in contact with the frame top.
HM400-1L 30-335
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF OPERATOR’S
DISASSEMBLY AND ASSEMBLY OF OPERATOR’S SEAT

● The procedure for disassembling and assembling the operator's seat assembly [with air suspension (manufactured by
ISRING HAUSEN)] is shown below.
A. Headrest E. Left-hand armrest

B. Seatback F. Suspension cover
C. Seat cushion G. Slide rails
D. Right-hand armrest
DISASSEMBLY
1. Headrest
A. Referring to the figure, check the positions of the two clips (2)
of headrest stay (1) on both sides.
30-336 HM400-1L
B. Apply force b to part a of each clip (2) in the direction of the
arrow to turn the clip. Release headrest stay (1) from part d of
the clip and pull out up headrest (3).
★ Pushing in both clips (2) simultaneously, remove headrest

(3).
2. Seatback
A. Disconnect three air hoses (5) from the rear left of seatback (4).
★ Before disconnecting the air hoses, check their types.
HM400-1L 30-337
B. Remove seatback hinge mounting bolt (6) (M8 bolt).
C. Bring seatback (4) down forward.
D. Apply force E to the right side of seatback (4) in the direction

of the arrow.
E. Applying the force to seatback (4), pull its right side up.
F. Slide seatback (4) sideway and remove it.
30-338 HM400-1L
3. Seat cushion
A. Push cushion adjuster lever (7) inward and slide seat cushion
(8) to the front end.
B. Push cushion stopper wire (9) down with screwdriver [1], etc.
C. Pull out seat cushion (8) forward and remove it.
4. Armrest
● The procedure for disassembling right-hand armrest (10) is
shown below.
(Disassemble left-hand armrest (11) similarly.)
HM400-1L 30-339
A. Remove plastic cap (12) from the armrest hinge.
★ Use a flat-head screwdriver, etc. to remove the cap.
B. Loosen armrest hinge mounting bolt (13).
C. Remove plastic cap (14), and then remove lower mounting bolt
(15A) (M8 bolt) of right-hand armrest (10).
D. Turn right-hand armrest (10) up by 180°.

★ If the armrest is not turned, you cannot apply the tool to
upper mounting bolt (15B).
E. Remove plastic cap (14) and upper mounting bolt (15B).
F. Remove right-hand armrest (10).

★ There are two position adjustment washers (16) installed
to each bolt between the armrest and seatback. Take care
not lose them.
30-340 HM400-1L
5. Suspension cover
A. Remove right-hand hinge cover (17).
B. Remove plastic plate (18) from the rear with screwdriver [1],
etc.
★ Take care not to damage the plastic plate by prying it off
forcibly with a screwdriver, etc.
C. Remove four suspension cover fixing rings (19).
D. Remove four mounting bolts (20), cushion rear fixing plate

(21), two cushion rails (22), and four bushings (23).
HM400-1L 30-341
E. Remove three metallic suspension cover clips (24).
F. Remove six plastic suspension cover clips (small) (25) and two
plastic suspension cover clips (large) (26).
★ Clips (small) (25):
Front upper part; two places
Each side; one place
Rear lower part; two places
Clips (large) (26):
Front lower part; two places
G. Remove suspension cover (27).

★ If you remove the suspension cover without performing
the work in steps E and F, the suspension cover may be
broken.
6. Rails
A. Turn over the seat assembly to set rails (28) on the upside.
B. Slide rails (28) to the rear end.
C. Remove one hexagon socket head bolt (29) and one lock
washer (30) from the front part of each rail.
30-342 HM400-1L
D. Slide rails (28) to the front end.
E. Remove one hexagon socket head bolt (29) and one lock
washer (30) from the rear part of each rail, and then remove
rails (28).
★ Take care not to lose height adjustment washers (31)

between the rails and suspension.
ASSEMBLY
1. Rails
A. Put height adjustment washers (31) between rails (28) and sus-
pension, and then set rails (28) in position.
B. Set rails (28) to the front end and install one lock washer (30)
and one hexagon socket head bolt (29) to each rail.
Hexagon socket head bolt: 21.4 - 27.6 N•m
HM400-1L 30-343
C. Set rails (28) to the rear end and install one lock washer (30)
and one hexagon socket head bolt (29) to each rail.
Hexagon socket head bolt: 21.4 - 27.6 N•m
2. Suspension cover
A. Set suspension cover (27) in position and install six plastic sus-
pension cover clips (small) (25) and two plastic suspension
cover clips (large) (26).
★ Clips (small) (25):
Front upper part; two places
Each side; one place
Rear lower part; two places
Clips (large) (26):
Front lower part; two places
B. Install three metallic suspension cover clips (24).
C. Set four bushings (23) and two cushion rails (22), and then
install cushion rear fixing plate (21), and four mounting bolts
(20).
Cushion rail mounting bolt: 21.4 - 27.6 N•m
30-344 HM400-1L
D. Install four suspension cover fixing rings (19).
E. Install plastic plate (18) to the rear.
F. Install right-hand hinge cover (17).
3. Armrest
● The procedure for assembling right-hand armrest (10) is shown
below.
(Assemble left-hand armrest (11) similarly.)
A. Install two position adjustment washers (16) for each bolt and
set right-hand armrest (10) in position.
HM400-1L 30-345
B. Tighten lower mounting bolt (15A) lightly and turn armrest
(10) by 180°.
C. Tighten upper mounting bolt (15B) lightly.
D. Tighten lower mounting bolt (15A) and upper mounting bolt

(15A) permanently.
Upper and lower armrest mounting bolt:

21.4 - 27.6 N•m
E. Install two plastic caps (14).
F. Tighten armrest hinge mounting bolt (13).

★ Tighten the bolt so that the arm will move smoothly.
● Operating effort at armrest end: 49 – 78.4 N•m
G. Install plastic cap (12).
4. Seat cushion
A. Slide in the seat cushion from the front of the fitting position.
★ If seat cushion (8) is slid to the rear, it is locked by cushion
stopper wire (9).
30-346 HM400-1L
5. Seatback
A. Insert the left side of seatback (4), and then lower and set the
right side.
B. Install seatback hinge mounting bolt (6) (M8 bolt).
Setback hinge mounting bolt: 21.4 - 27.6 N•m
C. Connect three air hoses (5) to the rear left of the seatback (4).
HM400-1L 30-347
6. Headrest
A. Insert headrest (3) in seatback (4).

★ Check that two clips (2) on both sides are locked securely.
30-348 HM400-1L
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
BRAKE HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
TO ENGINE CONTROLLER (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
TO ENGINE CONTROLLER (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
TO MAIN HARNESS INSIDE OF CAB (1/10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
TO MAIN HARNESS INSIDE OF CAB (10/10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
SWITCH PANEL (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
SWITCH PANEL (2/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-35
SWITCH PANEL (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
DISPLAY PANEL (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-39
DISPLAY PANEL (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41
RETARD CONTROLLER (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43
RETARD CONTROLLER (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
TO TRANSMISSION CONTROLLER (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-47
TO TRANSMISSION CONTROLLER (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-49
TO HARNESS OUTSIDE OF CAB (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-51
TO HARNESS OUTSIDE OF CAB (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-53
FUSE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-55
LOAD METER (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-57
LOAD METER (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-59
HM400-1L 90-1
OTHERS POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
12
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
90-2 HM400-1L
OTHERS STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
STEERING AND HOIST HYDRAULIC CIRCUIT DIAGRAM
HM400-1L 90-3
OTHERS DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
DIFFERENTIAL LOCK HYDRAULIC CIRCUIT DIAGRAM
90-4 HM400-1L
OTHERS BRAKE HYDRAULIC CIRCUIT DIAGRAM
12
BRAKE HYDRAULIC CIRCUIT DIAGRAM
90-5 HM400-1L
OTHERS BRAKE HYDRAULIC CIRCUIT DIAGRAM
HM400-1L 90-6
OTHERS AIR CONDITIONER
AIR CONDITIONER
90-7 HM400-1L
OTHERS AIR CONDITIONER
HM400-1L 90-8
OTHERS TO ENGINE CONTROLLER (1/2)
TO ENGINE CONTROLLER (1/2)
90-9 HM400-1L
HM400-1L 90-10
12
TO ENGINE CONTROLLER (2/2)
90-11 HM400-1L
12
HM400-1L 90-12
OTHERS TO MAIN HARNESS INSIDE OF CAB (1/10)
12
TO MAIN HARNESS INSIDE OF CAB (1/10)
90-13 HM400-1L
12
HM400-1L 90-14
12
90-15 HM400-1L
12
HM400-1L 90-16
12
90-17 HM400-1L
12
HM400-1L 90-18
12
90-19 HM400-1L
12
HM400-1L 90-20
12
90-21 HM400-1L
12
HM400-1L 90-22
12
90-23 HM400-1L
12
HM400-1L 90-24
12
90-25 HM400-1L
12
HM400-1L 90-26
12
90-27 HM400-1L
12
HM400-1L 90-28
12
90-29 HM400-1L
12
HM400-1L 90-30
12
90-31 HM400-1L
12
HM400-1L 90-32
OTHERS SWITCH PANEL (1/3)
12
SWITCH PANEL (1/3)
90-33 HM400-1L
12
HM400-1L 90-34
12
SWITCH PANEL (2/3)
90-35 HM400-1L
12
HM400-1L 90-36
12
SWITCH PANEL (3/3)
90-37 HM400-1L
12
HM400-1L 90-38
OTHERS DISPLAY PANEL (1/2)
12
DISPLAY PANEL (1/2)
90-39 HM400-1L
12
HM400-1L 90-40
12
DISPLAY PANEL (2/2)
90-41 HM400-1L
12
HM400-1L 90-42
OTHERS RETARD CONTROLLER (1/2)
12
RETARD CONTROLLER (1/2)
90-43 HM400-1L
12
HM400-1L 90-44
12
RETARD CONTROLLER (2/2)
90-45 HM400-1L
12
HM400-1L 90-46
OTHERS TO TRANSMISSION CONTROLLER (1/2)
12
TO TRANSMISSION CONTROLLER (1/2)
90-47 HM400-1L
12
HM400-1L 90-48
12
TO TRANSMISSION CONTROLLER (2/2)
90-49 HM400-1L
12
HM400-1L 90-50
OTHERS TO HARNESS OUTSIDE OF CAB (1/2)
12
TO HARNESS OUTSIDE OF CAB (1/2)
90-51 HM400-1L
12
HM400-1L 90-52
12
TO HARNESS OUTSIDE OF CAB (2/2)
90-53 HM400-1L
12
HM400-1L 90-54
OTHERS FUSE BLOCK
12
FUSE BLOCK
90-55 HM400-1L
OTHERS FUSE BLOCK
12
HM400-1L 90-56
OTHERS LOAD METER (1/2)
12
LOAD METER (1/2)
90-57 HM400-1L
12
HM400-1L 90-58
12
LOAD METER (2/2)
90-59 HM400-1L
12
HM400-1L 90-60
Komatsu America Corp.
DataKom Publications & Training PROPOSAL FOR MANUAL OR CSS REVISION
440 North Fairway Drive
Vernon Hills, IL. 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847)-970-4186
DATE: FOR INTERNAL USE ONLY -- No.PMR
NAME OF COMPANY: CITY:

PROPOSER
STATE OR PROVINCE:
DEPARTMENT: COUNTRY:
NAME: FAX:
MANUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service
MANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:
MANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:
BOOK DESCRIPTION
MACHINE MODEL & S/N:
MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS
PROBLEM:
Attach photos or sketches.

If more space is needed, use another sheet.
FOR INTERNAL USE ONLY
CORRECTIVE ACTION:
PROPFREV.FM 100903

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CEBM015301

SERIAL NUMBERS HM400-1L A10001 and UP

October 2005 Copyright 2005 Komatsu

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER

OPERATION AND MAINTENANCE MANUAL

FIELD ASSEMBLY MANUAL

HM400-1L pubinfok.fm 2/22/05

COMPLETE FORM DataKom Publications and Training Division

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91E 071403 CURRENT PRICES WILL BE CHARGED

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