Shop
Manual
HM400-2
ARTICULATED DUMP TRUCK
SERIAL NUMBERS HM400-2 2001 and up
A11001 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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
HM400-2
HM400-2 1
SEN00512-03 00 Index and foreword
01 Specification SEN00514-00
Specification and technical data SEN00515-00
40 Troubleshooting SEN00530-00
General information on troubleshooting SEN01107-00
Troubleshooting by failure code, General SEN01262-00
Troubleshooting by failure code, Part 1 SEN01108-00
Troubleshooting by failure code, Part 2 SEN01109-00
Troubleshooting by failure code, Part 3 SEN01110-00
2 HM400-2
00 Index and foreword SEN00512-03
HM400-2 3
SEN00512-03 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN00512-03
Organization list of the shop manual ....................................................................................... 2
Table of contents...................................................................................................................... 4
01 Specification
Specification and technical data SEN00515-00
Specification and technical data .................................................................................................. 2
Specification drawings ............................................................................................................. 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 6
Fuel, coolant and lubricants..................................................................................................... 7
4 HM400-2
00 Index and foreword SEN00512-03
Accumulator............................................................................................................................. 11
Slack adjuster .......................................................................................................................... 12
Brake ....................................................................................................................................... 14
Proportional reducing valve ..................................................................................................... 19
Brake system tank ................................................................................................................... 20
Parking brake .......................................................................................................................... 22
Parking brake caliper............................................................................................................... 24
Spring cylinder ......................................................................................................................... 25
Parking brake solenoid ............................................................................................................ 26
Undercarriage and frame SEN00522-00
Undercarriage and frame ............................................................................................................ 2
Suspension.............................................................................................................................. 2
Suspension cylinder ................................................................................................................ 7
Oscillation hitch ....................................................................................................................... 9
Hydraulic system SEN00523-00
Hydraulic system......................................................................................................................... 2
Steering, hoist oil pressure piping diagram.............................................................................. 2
Dump body control .................................................................................................................. 3
Hydraulic tank and filter ........................................................................................................... 4
Flow amp valve........................................................................................................................ 5
Steering valve .......................................................................................................................... 8
Steering cylinder ...................................................................................................................... 12
Hoist valve ............................................................................................................................... 14
EPC valve................................................................................................................................ 20
Brake cooling oil control valve (BCV) ...................................................................................... 21
Pilot check valve...................................................................................................................... 22
Hoist cylinder ........................................................................................................................... 23
Hydraulic pump........................................................................................................................ 24
Cab and its attachments SEN00524-00
Cab and its attachments.............................................................................................................. 2
Cab tilt ..................................................................................................................................... 2
Air conditioner.......................................................................................................................... 3
Electrical system, Part 1 SEN00525-00
Electrical system, Part 1.............................................................................................................. 2
Machine monitor system.......................................................................................................... 2
Electrical system, Part 2 SEN00526-00
Electrical system, Part 2.............................................................................................................. 2
Automatic shift control system ................................................................................................. 2
Transmission controller............................................................................................................ 5
Auto emergency steering system ............................................................................................ 32
Retarder control system .......................................................................................................... 33
Dump control lever .................................................................................................................. 42
Electrical system, Part 3 SEN00527-00
Electrical system, Part 3.............................................................................................................. 2
Sensors, switches.................................................................................................................... 2
KOMTRAX terminal system (if equipped)................................................................................ 9
HM400-2 5
SEN00512-03 00 Index and foreword
40 Troubleshooting
General information on troubleshooting SEN01107-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Check before troubleshooting.................................................................................................. 4
Classification and procedures for troubleshooting................................................................... 5
Connector pin Nos. and connection table................................................................................ 8
6 HM400-2
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HM400-2 7
SEN00512-03 00 Index and foreword
8 HM400-2
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Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit.............................. 24
Failure code [CA1627] Disconnection in bypass valve solenoid drive circuit .......................... 26
Failure code [CA1628] Trouble in bypass valve servo 1 ......................................................... 27
Failure code [CA1629] Trouble in bypass valve servo 2 ......................................................... 28
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor.............................. 30
Failure code [CA1632] Abnormally low signal in bypass valve lift sensor ............................... 32
Failure code [CA1633] Trouble in KOMNET............................................................................ 34
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor .......................... 36
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor......................... 38
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply.................... 40
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply ..................... 42
Failure code [CA2249] Low pressure in supply pump 2 .......................................................... 42
Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor..................... 44
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor ...................... 46
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit ................................. 48
Failure code [CA2352] Disconnection in EGR valve solenoid drive circuit.............................. 50
Failure code [CA2555] Disconnection in intake air heater relay .............................................. 50
Failure code [CA2556] Short circuit in intake air heater relay ................................................. 52
Troubleshooting by failure code, Part 5 SEN01112-00
Troubleshooting by failure code, Part 5....................................................................................... 3
Failure code [DAF9KM] Wrong connection of connector ........................................................ 3
Failure code [DAFRKR] Trouble in CAN communication (machine monitor) .......................... 4
Failure code [DAQ0KK] Lowering of source voltage ............................................................... 6
Failure code [DAQ0KT] Trouble in non-volatile memory ......................................................... 8
Failure code [DAQ2KK] Trouble in solenoid power supply system ......................................... 10
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) ............. 12
Failure code [DAQRKR] Trouble in CAN communication (Transmission controller) ............... 14
Failure code [DAQRMA] Disagreement of option setting (Transmission controller)................ 16
Failure code [DB10KT] Trouble in non-volatile memory .......................................................... 16
Failure code [DB12KK] Trouble in solenoid power supply system ......................................... 18
Failure code [DB13KK] Lowering of battery direct voltage ...................................................... 20
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) ..................... 22
Failure code [DB1QMA] Disagreement of option setting (Retarder controller)........................ 22
Failure code [DB1RKR] Trouble in CAN communication (Retarder controller) ....................... 24
Failure code [DB2RKR] Trouble in CAN communication (Engine controller) .......................... 26
Failure code [DD1ML4] Disagreement of accelerator-linked retarder switch signal ................ 28
Failure code [DDTHKA] Trouble in Hi clutch flow sensor valve............................................... 30
Failure code [DDTJKA] Trouble in Lo clutch flow sensor valve ............................................... 31
Failure code [DDTKKA] Trouble in 1st clutch flow sensor valve.............................................. 32
Failure code [DDTLKA] Trouble in 2nd clutch flow sensor valve............................................. 33
Failure code [DDTMKA] Trouble in 3rd clutch flow sensor valve............................................. 34
Failure code [DDTNKA] Trouble in reverse clutch flow sensor valve ...................................... 35
Failure code [DF10KA] Input of no lever signals ..................................................................... 36
Failure code [DF10KB] Input of multiple lever signals............................................................. 40
Failure code [DGF1KX] Transmission oil temperature out of range ........................................ 44
Failure code [DGR2KZ] Ground fault in brake oil temperature sensor (rear) .......................... 46
Failure code [DGR2L8] Disconnection in brake oil temperature sensor (rear) ........................ 48
Failure code [DGR3KZ] Ground fault in brake oil temperature sensor (center) ...................... 50
Failure code [DGR3L8] Disconnection in brake oil temperature sensor (center) .................... 52
Failure code [DGR4KZ] Ground fault in brake oil temperature sensor (front) ......................... 54
Failure code [DGR4L8] Disconnection in brake oil temperature sensor (front) ....................... 56
Failure code [DGR6KX] Steering oil temperature out of range................................................ 58
Troubleshooting by failure code, Part 6 SEN01113-00
Troubleshooting by failure code, Part 6....................................................................................... 4
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system........ 4
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil
pressure sensor system....................................................................................................... 6
HM400-2 9
SEN00512-03 00 Index and foreword
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor ................................. 8
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system................ 10
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system ................ 12
Failure code [DJF1KA] Disconnection in fuel level sensor system.......................................... 14
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS ........................... 16
Failure code [DK52KX] Trouble in dump lever potentiometer 1............................................... 18
Failure code [DK53L8] Trouble in dump lever potentiometer 2 ............................................... 20
Failure code [DK54KX] Trouble in dump positioner sensor ..................................................... 22
Failure code [DKH0KX] Pitch angle sensor signal out of range .............................................. 24
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system ....... 26
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor .............................. 27
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor
system.................................................................................................................................. 28
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor
system.................................................................................................................................. 29
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system ....... 30
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system ..... 31
Failure code [DV00KB] Short circuit in buzzer output circuit ................................................... 32
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output
system.................................................................................................................................. 34
Failure code [DW73KZ] Trouble in dump selector valve output system .................................. 36
Failure code [DW78KZ] Trouble in rear wheel BCV command output system ........................ 38
Failure code [DW79KZ] Trouble in front wheel BCV command output system ....................... 40
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing
valve 1.................................................................................................................................. 42
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid
pressure reducing valve ....................................................................................................... 44
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid
pressure reducing valve ....................................................................................................... 46
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid
pressure reducing valve ....................................................................................................... 48
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing
valve 2.................................................................................................................................. 50
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing
valve 1.................................................................................................................................. 52
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid
pressure reducing valve ....................................................................................................... 54
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid
pressure reducing valve ....................................................................................................... 56
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid
pressure reducing valve ....................................................................................................... 58
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing
valve 2.................................................................................................................................. 60
Troubleshooting by failure code, Part 7 SEN01114-00
Troubleshooting by failure code, Part 7....................................................................................... 4
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve............................ 4
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve .............................. 6
Failure code [DX13KY] Hot short in output circuit of dump EPC valve.................................... 8
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system......... 10
Failure code [DX15KZ] Trouble in front wheel differential lock command output system........ 12
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch
solenoid................................................................................................................................ 14
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch
solenoid................................................................................................................................ 16
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid.... 18
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid................... 19
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid ..................... 20
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid........................... 22
10 HM400-2
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HM400-2 11
SEN00512-03 00 Index and foreword
12 HM400-2
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HM400-2 13
SEN00513-00
HM400-2
HM400-2 1
SEN00513-00 00 Index and foreword
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 HM400-2
00 Index and foreword SEN00513-00
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r l y c a r e fu l t o c he c k t h a t t h ey ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
HM400-2 3
SEN00513-00 00 Index and foreword
4 HM400-2
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q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
HM400-2 5
SEN00513-00 00 Index and foreword
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
6 HM400-2
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3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
HM400-2 7
SEN00513-00 00 Index and foreword
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 HM400-2
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HM400-2 9
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10 HM400-2
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3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
HM400-2 11
SEN00513-00 00 Index and foreword
12 HM400-2
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2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
HM400-2 13
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14 HM400-2
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4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
HM400-2 15
SEN00513-00 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
16 HM400-2
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6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 ) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
HM400-2 17
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In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
18 HM400-2
00 Index and foreword SEN00513-00
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
HM400-2 19
SEN00513-00 00 Index and foreword
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 HM400-2
00 Index and foreword SEN00513-00
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
HM400-2 21
SEN00513-00 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
22 HM400-2
00 Index and foreword SEN00513-00
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
HM400-2 23
SEN00513-00 00 Index and foreword
a Fig. A a Fig. B
24 HM400-2
00 Index and foreword SEN00513-00
HM400-2 25
SEN00513-00 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
26 HM400-2
00 Index and foreword SEN00513-00
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
HM400-2 27
SEN00513-00 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
28 HM400-2
00 Index and foreword SEN00513-00
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
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
HM400-2 29
SEN00513-00 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 HM400-2
00 Index and foreword SEN00513-00
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
HM400-2 31
SEN00513-00 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be 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 to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
32 HM400-2
SEN00513-00 00 Index and foreword
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
34 HM400-2
SEN00515-00
HM400-2
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification drawings.......................................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ......................................................................................................................................... 6
Fuel, coolant and lubricants ................................................................................................................. 7
HM400-2 1
SEN00515-00 01 Specification
2 HM400-2
01 Specification SEN00515-00
Specifications 1
Unloaded kg 32,460
Max. payload kg 37,000
Overall weight kg 68,960
Struck m3 16.5
Dump body capacity
Heaped (2:1) m 3 22.3
Performance
HM400-2 3
SEN00515-00 01 Specification
kPa
Tire inflation pressure 0.372 {3.8}
{kg/cm2}
4 HM400-2
01 Specification SEN00515-00
Hoist cylinder
Type 2-stage piston type
(only 2nd stage double-acting)
Cylinders
HM400-2 5
SEN00515-00 01 Specification
Weight table 1
This weight table is a guide for use when transporting or handling components.
Unit: kg
6 HM400-2
01 Specification SEN00515-00
HM400-2 7
SEN00515-00 01 Specification
Reservoir Transmission
Front Rear Front
Engine case Hydraulic
suspension suspension differential
oil pan (Incl. brake tank
(each) (each) Case
Capacity oil tank)
Reservoir
Front final Center Center final Rear Rear final
Cooling
drive case differential drive case differential drive case Fuel tank
system
(each) Case (each) Case (each)
Capacity
8 HM400-2
SEN00515-00 01 Specification
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
10 HM400-2
SEN00517-00
HM400-2
HM400-2 1
SEN00517-00 10 Structure, function and maintenance standard
1. Aftercooler Specifications
2. Water filler Radiator
3. Reservoir tank • Core type: CF4-5
4. Upper tank • Total heat dissipation area: 90.68m2
5. Lower tank Torque converter oil cooler
6. Oil cooler (steering, torque converter) • Core type: PTO-LS
7. Sub tank • Total heat dissipation area: 4.0655m2
Steering oil cooler
A: From thermostat • Core type: PTO-OL
B: To water pump • Total heat dissipation area: 0.896m2
C: From rear brake
D: To oil filter
E: From hoist valve
F: To hydraulic tank
G: From water pump
2 HM400-2
10 Structure, function and maintenance standard SEN00517-00
Output shaft 1
HM400-2 3
SEN00517-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Weaar of oil seal contact sur- Standard size Repair limit Repair or
5
face of coupling 95 94.7 replace
4 HM400-2
SEN00517-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
6 HM400-2
SEN00518-00
HM400-2
HM400-2 1
SEN00518-00 10 Structure, function and maintenance standard
2 HM400-2
10 Structure, function and maintenance standard SEN00518-00
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling and brake system pump (SDR(30)63+SA(1)12)
5. Power train, front brake cooling, differential lock control pump (SDR(30)80+SB(1)12+8)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SDR(30)100+100+SB(1)8)
9. Transmission
10. 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
HM400-2 3
SEN00518-00 10 Structure, function and maintenance standard
4 HM400-2
10 Structure, function and maintenance standard SEN00518-00
1. Engine
2. Output shaft
3. Front drive shaft
4. Brake cooling and brake system pump (SDR(30)63+SA(1)12)
5. Power train pump (SDR(3)80)
6. PTO
7. Torque converter
8. Steering, hoist control pump (SDR(30)100+100+SB(1)8)
9. Transmission
10. Oscillation hitch
11. Center drive shaft
12. Front differential
13. Front limited slip differential
14. Tire
15. Final drive (front)
16. Brake (front)
17. Rear drive shaft (front)
18. Center differential
19. Center limited slip differential
20. Tire
21. Final drive (center)
22. Brake (center)
23. Rear drive shaft (rear)
24. Rear differential
25. Rear limited slip differential
26. Tire
27. Final drive (rear)
28. Brake (rear)
29. Interaxle differential lock
HM400-2 5
SEN00518-00 10 Structure, function and maintenance standard
Drive shaft 1
6 HM400-2
SEN00518-00 10 Structure, function and maintenance standard
8 HM400-2
10 Structure, function and maintenance standard SEN00518-00
1. Engine
2. Torque converter
3. Transmission
4. Oil cooler
5. Power train, brake cooling return filter
6. Rear brake cooling and brake system pump (SDR(30)63+SA(1)25)
7. Brake system tank
8. Power train, front brake cooling, differential control pump (SDR(30)80+SB(1)12+8)
9. Hydraulic tank
10. Front brake cooling valve
11. Center brake cooling valve
HM400-2 9
SEN00518-00 10 Structure, function and maintenance standard
Torque converter 1
Unit: mm
No. Check item Criteria Remedy
10 HM400-2
10 Structure, function and maintenance standard SEN00518-00
HM400-2 11
SEN00518-00 10 Structure, function and maintenance standard
12 HM400-2
10 Structure, function and maintenance standard SEN00518-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 13
SEN00518-00 10 Structure, function and maintenance standard
• When the lockup clutch is “disengaged“, drive • When the lockup clutch is “engaged“, drive case
case (4) and turbine (6) are disconnected, and (4) and turbine (6) are connected, and stator (9)
the torque converter functions as normal. is dragged and turned by the pump (5) and tur-
• The engine power is transferred through the bine (6).
damper and drive shaft to coupling (1). • The engine power is transferred through the
• The power transferred to coupling (1) rotates in- damper and drive shaft to coupling (1).
put shaft (2), clutch housing (3), drive case (4) • The power transferred to coupling (1) rotates in-
and pump (5) integrally. put shaft (2), clutch housing (3), drive case (4)
• The power transferred to the pump (5) rotates and pump (5) integrally.
turbine (6) using the oil as a medium. • As the lock up clutch is engaged, the power
• The power is transferred from turbine (6) to boss transferred to the drive case (4) directly rotates
(7) and to transmission input shaft (8) that is turbine (6).
splined to boss (7). • The power is transferred from turbine (6) to boss
(7) and to transmission input shaft (8) that is
splined to boss (7).
14 HM400-2
10 Structure, function and maintenance standard SEN00518-00
Oil flow
• The oil flows through the main relief valve and its
pressure is reduced to below the set pressure by
the torque converter relief valve. It then flows
into inlet port (A), goes through the oil passages
of stator shaft (1), and flows into pump (2).
• The oil is given centrifugal force by pump (2) and
flows into turbine (3) to transfer its energy to tur-
bine (3).
• The oil from turbine (3) is sent to stator (4) and
flows into pump (2) again. However, part of the
oil passes between turbine (3) and stator (4) and
is sent from outlet port (B) to the oil cooler to be
cooled. It is then used to lubricate the transmis-
sion.
HM400-2 15
SEN00518-00 10 Structure, function and maintenance standard
Transmission 1
16 HM400-2
10 Structure, function and maintenance standard SEN00518-00
Number of
Clutch No. Number of discs
plates
FL clutch 12 11
R clutch 12 11
FH clutch 10 9
1st clutch 12 11
3rd clutch 8 7
2nd clutch 14 13
HM400-2 17
SEN00518-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
18 HM400-2
10 Structure, function and maintenance standard SEN00518-00
HM400-2 19
SEN00518-00 10 Structure, function and maintenance standard
20 HM400-2
10 Structure, function and maintenance standard SEN00518-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 21
SEN00518-00 10 Structure, function and maintenance standard
FL, R clutch
Unit: mm
No. Check item Criteria Remedy
22 HM400-2
10 Structure, function and maintenance standard SEN00518-00
1. FH clutch gear (number of teeth: 57) 5. 1st clutch gear (number of teeth: 30)
2. FH clutch 6. Upper gear (number of teeth: 49)
3. FH, 1st cylinder (number of teeth: 67) 7. Upper shaft
4. 1st clutch
Unit: mm
No. Check item Criteria Remedy
HM400-2 23
SEN00518-00 10 Structure, function and maintenance standard
1. 3rd clutch gear (number of teeth: 25) 5. 2nd clutch gear (number of teeth: 43)
2. 3rd clutch 6: Lower gear (number of teeth: 54)
3. 2nd, 3rd cylinder (number of teeth: 62) 7. Lower shaft
4. 2nd clutch
Unit: mm
No. Check item Criteria Remedy
24 HM400-2
10 Structure, function and maintenance standard SEN00518-00
HM400-2 25
SEN00518-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
26 HM400-2
10 Structure, function and maintenance standard SEN00518-00
• The oil sent from the ECMV flows through the oil • When the oil sent from the ECMV is shut off,
passage of shaft (1), is pressure-fed to the back pressure of the oil acting on the back face of pis-
side of piston (2), and pushes piston (2) to the ton (2) goes down.
right. • Piston (2) is pushed back to the left by the ten-
• Piston (2) compresses plates (3) and discs (4) sion of wave spring (7).
and the rotation of discs (4) is stopped by the • The friction force between plates (3) and discs
frictional force. (4) is eliminated and shaft (1) and clutch gear (5)
• As the internal teeth of disc (4) are meshed with are released.
the clutch gear (5), shaft (1) and cluch gear (5) • When the clutch is released, the oil in the back
transfer the power as a unit. side of piston is drained by the centrifugal force
• The oil is drained from oil drain hole (6), but the through oil drain hole (6) to prevent the clutch
drain amount is less than the amount of oil sup- from being partially applied.
plied, so there is no influence on the actuation of
the clutch.
a Oil drain hole (6) forms part of the structure of
only the 2nd, 3rd and differential lock clutches.
HM400-2 27
SEN00518-00 10 Structure, function and maintenance standard
• When the transmission is set to the forward 1st • 1st clutch (11) is engaged, so the power trans-
speed, the FL clutch (3) and 1st clutch (11) are mitted to FH, 1st cylinder gear (8) passes
engaged.The power from the torque converter is through 1st clutch (11), and goes from 1st gear
transmitted to input shaft (1), and then transmit- (12) to 2nd, 3rd cylinder (14). It then goes
ted to front and rear output shafts (28) and (29). through lower gear (19) to output gear (20), and
• FL clutch (3) and 1st clutch (11) hold each clutch is transmitted to carrier (21).
disc in position with the oil pressure applied to • When the differential lock switch is “off“, the front
the piston. output force passes from planetary gear (25)
• The power from the torque converter is trans- through sun gear (26) and is transmitted to front
ferred from input shaft (1) through FL clutch (3), output shaft (28). The rear output force passes
goes to FL gear (5), and is then transferred to from planetary gear (25) through ring gear (27),
FH, 1 st cylinder (8). and is transmitted to rear output shaft (29).
a If the differential lock is “on“, see Forward 2nd
speed.
28 HM400-2
10 Structure, function and maintenance standard SEN00518-00
• When the transmission is set to the forward 2nd • 1st clutch (11) is engaged, so the power trans-
speed, the FH clutch (10) and 1st clutch (11) are mitted to FH, 1st cylinder gear (8) passes
engaged.The power from the torque converter is through 1st clutch (11), and goes from 1st gear
transmitted to input shaft (1), and then transmit- (12) to 2nd, 3rd cylinder (14). It then goes
ted to front and rear output shafts (28) and (29). through lower gear (19) to output gear (20), and
• FH clutch (10) and 1st clutch (11) hold each is transmitted to carrier (21).
clutch disc in position with the oil pressure ap- • When the differential lock switch is “on“, the front
plied to the piston. output force passes from housing (22) through
• The power from the torque converter is trans- differential lock clutch (23) to clutch hub (24) and
ferred from input shaft (1) to input gear (2) and is transmitted to front output shaft (28). The rear
goes to FH gear (9), passes through FH clutch output force passes from planetary gear (25)
(10), and is then transferred to FH, 1st cylinder through ring gear (27), and is transmitted to rear
(8). output shaft (29).
a If the differential lock is “off“, see Forward 1st
speed.
HM400-2 29
SEN00518-00 10 Structure, function and maintenance standard
• When the transmission is set to the forward 3rd • 2nd clutch (17) is engaged, so the power trans-
speed, the FL clutch (3) and 2nd clutch (17) are mitted to 2nd gear (15), passes through 2nd
engaged.The power from the torque converter is clutch (17), to 2nd, 3rd cylinder (14). It then
transmitted to input shaft (1), and then transmit- goes through lower gear (19) to output gear (20)
ted to front and rear output shafts (28) and (29). and is transmitted to differential lock carrier (21).
• FL clutch (3) and 2nd clutch (17) hold each a The diagram above shows the situation when
clutch disc in position with the oil pressure ap- the differential lock is “off“.
plied to the piston. a For details of the actuation when the differential
• The power from the torque converter is trans- lock is “off“, see Forward 1st speed; for details
ferred from input shaft (1) through FL clutch (3), of the actuation when the differential lock is
goes to FL gear (5), and is then transferred “on“, see Forward 2nd speed.
through FH, 1st cylinder gear (8) and upper gear
(13), and goes to 2nd gear (15).
30 HM400-2
10 Structure, function and maintenance standard SEN00518-00
• When the transmission is set to the forward 4th • 2nd clutch (17) is engaged, so the power trans-
speed, the FH clutch (10) and 2nd clutch (17) mitted to 2nd gear (15), passes through 2nd
are engaged. The power from the torque con- clutch (17), to 2nd, 3rd cylinder (14). It then
verter is transmitted to input shaft (1), and then goes through lower gear (19) to output gear (20)
transmitted to front and rear output shafts (28) and is transmitted to differential lock carrier (21).
and (29). a The diagram above shows the situation when
• FH clutch (10) and 2nd clutch (17) hold each the differential lock is “on“.
clutch disc in position with the oil pressure ap- a For details of the actuation when the differential
plied to the piston. lock is “off“, see Forward 1st speed; for details
• The power from the torque converter is trans- of the actuation when the differential lock is
ferred from input shaft (1), goes to idler gear (2) “on“, see Forward 2nd speed.
and FH gear (9), passes through FH clutch (10),
and is then transferred through FH, 1st cylinder
(8) and idler gear (13), and is transferred to 2nd
gear (15).
HM400-2 31
SEN00518-00 10 Structure, function and maintenance standard
• When the transmission is set to the forward 5th • 3rd clutch (18) is engaged, so the power trans-
speed, the FL clutch (3) and 3rd clutch (18) are mitted to 3rd gear (16), passes through 3rd
engaged. The power from the torque converter clutch (18), to 2nd, 3rd cylinder (14). It then
is transmitted to input shaft (1), and then trans- goes through lower gear (19) to output gear (20),
mitted to front and rear output shafts (28) and and is transmitted to differential lock carrier (21).
(29). a The diagram above shows the situation when
• FL clutch (3) and 3rd clutch (18) hold each clutch the differential lock is “off“.
disc in position with the oil pressure applied to a For details of the actuation when the differential
the piston. lock is “off“, see Forward 1st speed; for details
• The power from the torque converter is trans- of the actuation when the differential lock is
ferred from input shaft (1) through FL clutch (3), “on“, see Forward 2nd speed.
goes to FL gear (5), and is then transferred
through FH, 1st cylinder gear (8) to 3rd gear(16).
32 HM400-2
10 Structure, function and maintenance standard SEN00518-00
• When the transmission is set to the forward 6th • 3rd clutch (18) is engaged, so the power trans-
speed, the FL clutch (10) and 3rd clutch (18) are mitted to 3rd gear (16), passes through 3rd
engaged. The power from the torque converter clutch (18), to 2nd, 3rd cylinder (14). It then
is transmitted to input shaft (1), and then trans- goes through lower gear (19) to output gear (20),
mitted to front and rear output shafts (28) and and is transmitted to differential lock carrier (21).
(29). a The diagram above shows the situation when
• FH clutch (10) and 3rd clutch (18) hold each the differential lock is “on“.
clutch disc in position with the oil pressure ap- a For details of the actuation when the differential
plied to the piston. lock is “off“, see Forward 1st speed; for details
• The power from the torque converter is trans- of the actuation when the differential lock is
ferred from input shaft (1), goes to idler gear (2) “on“, see Forward 2nd speed.
and FH gear (9), passes through FH clutch (10),
and is then transferred through FH, 1st cylinder
(8) to 3rd gear (16).
HM400-2 33
SEN00518-00 10 Structure, function and maintenance standard
• When the transmission is set to the reverse 1st • 1st clutch (11) is engaged, so the power trans-
speed, the R clutch (4) and 1st clutch (11) are mitted to FH, 1st cylinder gear (8) passes
engaged. The power from the torque converter through 1st clutch (11), and goes from 1st gear
is transmitted to input shaft (1), and then trans- (12) to 2nd, 3rd cylinder (14). It then goes
mitted to front and rear output shafts (28) and through lower gear (19) to output gear (20), and
(29). is transmitted to carrier (21).
• R clutch (4) and 1st clutch (11) hold each clutch a The diagram above shows the situation when
disc in position with the oil pressure applied to the differential lock is “off“.
the piston. a For details of the actuation when the differential
• The power from the torque converter is trans- lock is “off“, see Forward 1st speed; for details
ferred from input shaft (1) through R clutch (4), of the actuation when the differential lock is
goes to R gear (6), is rotated in the opposite di- “on“, see Forward 2nd speed.
rection by R idler gear (7), passes through upper
gear (13), and is then transferred to FH, 1st cyl-
inder (8).
34 HM400-2
10 Structure, function and maintenance standard SEN00518-00
HM400-2 35
SEN00518-00 10 Structure, function and maintenance standard
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
A: To clutch *1:
P: From pump Operated clutches Stamp of the nameplates
T: Drain
FL,FH,R,1st A*******
Dr: Drain
P1: Clutch oil pressure pickup port 2nd,3rd E*******
36 HM400-2
10 Structure, function and maintenance standard SEN00518-00
HM400-2 37
SEN00518-00 10 Structure, function and maintenance standard
38 HM400-2
10 Structure, function and maintenance standard SEN00518-00
• If current is applied to proportional solenoid (1) • If current flows in proportional solenoid (1), the
with no oil in the clutch, the oil pressure force solenoid generates thrust in proportion to the
balanced with the solenoid force is applied to current. This thrust of the solenoid is balanced
chamber (B) and pushes pressure control valve with the sum of the thrust generated by the oil
(3) to the left.This opens pump port (P) and pressure in clutch port and the tension of pres-
clutch port (A) to feed oil in the clutch. When the sure control valve spring (2), and then the pres-
clutch is filled with oil, pressure detection valve sure is settled.
(4) actuates to turn “on“ fill switch (5).
HM400-2 39
SEN00518-00 10 Structure, function and maintenance standard
A: To clutch *1:
P: From pump Operated clutches Stamp of the nameplates
T: Drain Lock up,
Dr: Drain K*******
differential lock
P1: Clutch oil pressure pickup port
40 HM400-2
10 Structure, function and maintenance standard SEN00518-00
Outline
ECMV for lockup clutch ECMV for differential lock clutch
• This valve acts to set the lockup clutch oil pres- • For each ECMV, 1 proportional solenoid is in-
sure to the set pressure, and also to switch the stalled.
lockup clutch. The proportional solenoid generates thrust
It forms a modulation wave pattern, so the shown below according to the command current
lockup clutch is engaged smoothly to reduce from the controller.
the shock when shifting gear. In addition, it pre- The thrust generated by the proportional sole-
vents generation of peak torque in the power noid is applied to the pressure control valve
train. As a result, it provides a comfortable ride spool to generate oil pressure as shown in the
for the operator and greatly increases the dura- figure below. Accordingly, the thrust is changed
bility of the power train. by controlling the command current to operate
the pressure control valve to control the flow
Torque converter travel o direct travel and pressure of the oil.
HM400-2 41
SEN00518-00 10 Structure, function and maintenance standard
Operation
Clutch “disengaged“ (released) When clutch is “engaged“ (fixed)
• Under the condition where any current is not • If current is applied to proportional solenoid (1),
sent to the proportional solenoid (1), pressure the oil pressure force balanced with the solenoid
control valve (3) drains the oil from clutch port force is applied to chamber (B) and pushes pres-
(A) through drain port (T). sure control valve (3) to the left. As a result, the
circuit between pump port (P) and clutch port (A)
opens, and oil starts to fill the clutch.
• When the clutch is filled with oil, the propulsion
force of the solenoid, the propulsion force gener-
ated by the oil pressure in the clutch port, and
the tension of pressure control valve spring (2)
come into balance, and the pressure is adjusted.
42 HM400-2
10 Structure, function and maintenance standard SEN00518-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 43
SEN00518-00 10 Structure, function and maintenance standard
Operation
44 HM400-2
SEN00518-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
46 HM400-2
SEN00519-00
HM400-2
HM400-2 1
SEN00519-00 10 Structure, function and maintenance standard
1. Drive shaft
2. Front differential
3. Brake
4. Final drive
2 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Center
1. Center axle
2. Center differential
3. Brake
4. Final drive
5. Oil filler port / level plug
6. Drain plug
HM400-2 3
SEN00519-00 10 Structure, function and maintenance standard
Rear
1. Drain plug
2. Rear axle
3. Oil filler port / level plug
4. Rear differential
5. Brake
6. Final drive
4 HM400-2
SEN00519-00 10 Structure, function and maintenance standard
Differential 1
(Machine with differential lock 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
6 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 7
SEN00519-00 10 Structure, function and maintenance standard
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)
8 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 9
SEN00519-00 10 Structure, function and maintenance standard
Rear
10 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
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 90f, 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.
When turning
• When the machine is turned, the speed that the
wheels turn on the left and right sides is differ-
ent, so pinion gear (6) and side gear (3) inside
the differential rotate according to the difference
in the turning speed on the left and right sides,
and transmit the power of differential case (2) to
the left and right shafts.
HM400-2 11
SEN00519-00 10 Structure, function and maintenance standard
12 HM400-2
SEN00519-00 10 Structure, function and maintenance standard
14 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 15
SEN00519-00 10 Structure, function and maintenance standard
Center
16 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 17
SEN00519-00 10 Structure, function and maintenance standard
Rear
18 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 19
SEN00519-00 10 Structure, function and maintenance standard
20 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 21
SEN00519-00 10 Structure, function and maintenance standard
22 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Normal 1 1 2 (1)
differential
<When turning>
The side gear built into the limited slip differential is
the same as the gear used on the normal differential,
so the difference in rotation of the inside and outside
wheels generated when turning can be generated
smoothly.
HM400-2 23
SEN00519-00 10 Structure, function and maintenance standard
Final drive 1
Front
1. Axle shaft
2. Ring gear (No. of teeth: 67)
3. Planet gear (No. of teeth: 24)
4. Planet carrier
5. Sun gear (No. of teeth: 17)
6. Drain plug
7. Brake
24 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 25
SEN00519-00 10 Structure, function and maintenance standard
Center, rear
26 HM400-2
10 Structure, function and maintenance standard SEN00519-00
Function
• The final drive uses a planetary gear mechanism
to reduce the speed in order to give a large drive
force, and transmits this drive force to the tires.
Operation
• The power from the differential passing through
axle shaft (1) is transmitted to sun gear (5) and
then goes to planet gear (3).
The planet gear rotates on the inside of fixed
ring gear (2) and transmits the reduced speed
to planetary carrier (4). This power is then
transmitted to the wheels that are installed to
the planetary carrier.
HM400-2 27
SEN00519-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
28 HM400-2
SEN00520-00
HM400-2
HM400-2 1
SEN00520-00 10 Structure, function and maintenance standard
Steering system 1
Steering column 1
1. Steering shaft
2. Steering column
3. Lock lever
4. Yoke
5. Join shaft
6. Steering valve
2 HM400-2
SEN00520-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
4 HM400-2
SEN00521-00
HM400-2
HM400-2 1
SEN00521-00 10 Structure, function and maintenance standard
Brake system 1
Brake piping 1
2 HM400-2
10 Structure, function and maintenance standard SEN00521-00
HM400-2 3
SEN00521-00 10 Structure, function and maintenance standard
Brake valve 1
4 HM400-2
10 Structure, function and maintenance standard SEN00521-00
HM400-2 5
SEN00521-00 10 Structure, function and maintenance standard
6 HM400-2
10 Structure, function and maintenance standard SEN00521-00
HM400-2 7
SEN00521-00 10 Structure, function and maintenance standard
8 HM400-2
10 Structure, function and maintenance standard SEN00521-00
HM400-2 9
SEN00521-00 10 Structure, function and maintenance standard
10 HM400-2
10 Structure, function and maintenance standard SEN00521-00
Accumulator 1
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
• The accumulator is installed between the accu-
mulator charge valve and the brake valve. It is
charged with nitrogen gas between cylinder (3)
and free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydraulic
pump or to maintain the braking force and to
make it possible to operate the machine if the
engine should stop.
Specifications
Gas used: Nitrogen gas
Gas capacity: 4,000 cc
Charging pressure: 4.4 ± 0.15MPa
{45 ± 1.5kg/cm2} (at 20 °C ± 5 °C)
HM400-2 11
SEN00521-00 10 Structure, function and maintenance standard
Slack adjuster 1
1. Breather
2. Cylinder
3. Check valve
4. Spring
5. Piston
A: Inlet port
B: Outlet port
Unit: mm
No. Check item Criteria Remedy
12 HM400-2
10 Structure, function and maintenance standard SEN00521-00
Function
• The slack adjuster is installed in the brake oil line
from the brake valve to the brake piston. It acts
to keep a constant time lag when the brake is
operated.
Operation
HM400-2 13
SEN00521-00 10 Structure, function and maintenance standard
Brake 1
Front
1. Stud bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
14 HM400-2
10 Structure, function and maintenance standard SEN00521-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 15
SEN00521-00 10 Structure, function and maintenance standard
Center, rear
1. Bolt
2. Cylinder
3. Brake piston
4. Disc
5. Plate
6. Hub gear (No. of teeth: 112)
7. Outer gear (No. of teeth: 164)
16 HM400-2
10 Structure, function and maintenance standard SEN00521-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 17
SEN00521-00 10 Structure, function and maintenance standard
Function
• There are wet-type multiple disc brakes installed
to all of the six wheels.
Operations
• When the brake pedal is depressed, pressure oil
from the brake valve moves brake piston (3) to
the right in the direction of the arrow. This press-
es disc (7) and plate (6) together and generates
friction between the disc and plate. The wheel is
rotating together with the disc, so this friction re-
duces the travel speed and stops the machine.
18 HM400-2
10 Structure, function and maintenance standard SEN00521-00
1. Filter Function
2. Connector • The proportional reducing valve is a valve used
3. Solenoid assembly for retarder control. It is installed between the
brake valve and the system tank in the brake cir-
A: To brake valve cuit.
P: From accumulator It varies the discharge pressure of the pressure
T: To brake system tank oil in accordance with the turning angle of the
retarder control lever, so the retarder control
can be carried out as desired.
HM400-2 19
SEN00521-00 10 Structure, function and maintenance standard
1. Boss
2. Return tube
3. Suction tube
A: To hydraulic pump
B: From accumulator charge valve
C: Oil filler port
D: Drain port
20 HM400-2
SEN00521-00 10 Structure, function and maintenance standard
Parking brake 1
22 HM400-2
10 Structure, function and maintenance standard SEN00521-00
Unit: mm
No. Check item Criteria Remedy
Rebuid
(Thickness of
Min. 20
5 Thickness of disc 25 disc must not be
under 20 mm)
Max. 20
Thickness of pad (including Replace
6 21.5 11.5
thickness of plate)
Standard dimen- Standard Allowable
Tolerance
sion of blade clearance clearance
0
22.3
-0.3
Clearance between blade and Correct or
7 Standard
brake assembly Tolerance replace
dimension of 1.0 ± 0.4 1.5
brake assembly
+0.4
22.3
-0.1
HM400-2 23
SEN00521-00 10 Structure, function and maintenance standard
1. Adjuster Outline
2. Piston • A piston guide is installed to caliper (5). Piston
3. Piston shaft (2) and piston shaft (3) are inserted, and the ro-
4. Pad tation of piston shaft (3) moves piston (2) in the
5. Caliper axial direction to bring pad (4) into tight contact.
• The adjuster (1) is joined by a spline to the spline
side of piston shaft (3).
Pad (4) is inserted together with caliper (5) into
the caliper mounting plate and is held in posi-
tion.
24 HM400-2
10 Structure, function and maintenance standard SEN00521-00
Spring cylinder 1
HM400-2 25
SEN00521-00 10 Structure, function and maintenance standard
26 HM400-2
SEN00521-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
28 HM400-2
SEN00522-00
HM400-2
HM400-2 1
SEN00522-00 10 Structure, function and maintenance standard
2 HM400-2
10 Structure, function and maintenance standard SEN00522-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 3
SEN00522-00 10 Structure, function and maintenance standard
Rear
4 HM400-2
10 Structure, function and maintenance standard SEN00522-00
1. Arm
2. Equalizer bar
3. Lateral rod (center)
4. Spring
5. Rear suspension
6. Lateral rod (rear)
HM400-2 5
SEN00522-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Function
1. Front suspension
The front suspension cylinder has the function of a
shock absorber and spring. It is joined to the arm
and main frame by a spherical bearing, and the arm
oscillates according to the extension and retraction
of the front suspension cylinder.
The main frame and arm are joined by a lateral rod
and receive the lateral load.
6 HM400-2
10 Structure, function and maintenance standard SEN00522-00
Suspension cylinder 1
HM400-2 7
SEN00522-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
1. Retracting action
When the machine is traveling and it hits a
bump or object on the road, the wheels are
pushed up, and the cylinder rod is pushed
inside the cylinder.
When this happens, the nitrogen gas inside
chamber (2) is compressed, the oil in chamber
(1) is sent through both orifices (4) and (5) to
cavity (3), and cavity (3) is filled more quickly
than when extending.
2. Extending action
When the machine has passed any bump or
object on the road surface, the cylinder rod is
pushed up by the weight of the wheels and axle
and the pressure of the nitrogen inside chamber
(2).
As a result, the amount of oil in cavity (3) is
reduced, and pressure is applied to the oil
remaining in cavity (3).
This pressurized oil closes orifice (4) with check 1. Oil chamber
ball (6), and is sent to chamber (1) through only 2. Nitrogen gas chamber
orifice (5), so the flow of oil passing through the 3. Cavity
orifice is controlled so that it is less than during 4. Orifice
retraction. 5. Orifice
In this way, the amount of oil returning to cham- 6. Check ball
ber (1) is restricted to provide a shock absorb-
ing effect.
8 HM400-2
10 Structure, function and maintenance standard SEN00522-00
Oscillation hitch 1
HM400-2 9
SEN00522-00 10 Structure, function and maintenance standard
10 HM400-2
10 Structure, function and maintenance standard SEN00522-00
Unit: mm
No. Check item Criteria Remedy
–
2 Standard shim thickness –
Clearance between bushing -0.036 +0.054 0.036 –
3 115 -0.090 0 0.144 –
and front frame
Clearance between shaft and -0.036 +0.054 0.036 –
4 bushing 85 -0.058 0 0.112 –
Outline
• The front frame and the rear frame are connect- • In addition, the output from the transmission is
ed by the oscillation hitch. transmitted from center drive shaft (3) to cou-
• Front frame (2) is connected with bearings and pling (9). It is then transmitted from coupling
pins (6) and (12); rear frame (4) is connected (11) through the rear drive shaft to the rear axle.
with a spacer, retainer, and bearing. This makes
it possible for the front and rear frames to articu-
late and oscillate.
HM400-2 11
SEN00522-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
12 HM400-2
SEN00523-00
HM400-2
HM400-2 1
SEN00523-00 10 Structure, function and maintenance standard
Hydraulic system 1
Steering, hoist oil pressure piping diagram 1
2 HM400-2
10 Structure, function and maintenance standard SEN00523-00
HM400-2 3
SEN00523-00 10 Structure, function and maintenance standard
4 HM400-2
10 Structure, function and maintenance standard SEN00523-00
HM400-2 5
SEN00523-00 10 Structure, function and maintenance standard
Operation
Operation
1. At neutral
• Port (P) of steering unit (7) is closed and the flow • For priority valve (2) also, the oil is drained from
amp valve is closed at chamber M of pressure relief valve (1).
control valve (3). Before starting, priority valve (2) is pushed
• Ports (L), (R), and (T) of steering unit (7) are strongly to the left by the spring, so in reality,
connected to each other, so the oil passes port (EF) of the flow amp valve is almost closed.
through port (T) of the flow amp valve and is • At the same time as the engine starts, oil flows
drained to the hydraulic tank. to port (HP) of the flow amp valve and then flows
By connecting in this way, directional valve (6) to port (P) of steering unit (7). At the same time,
is always held at the neutral position by the the pilot pressure that is connected to port (PP)
springs on both sides. For this reason, at the suddenly rises. As a result of balancing with
neutral position, the reaction or impact from the the spring and moving to the right, port (EF)
steering cylinder is not transmitted to steering opens and the oil flows to the hoist piping.
unit (7).
6 HM400-2
10 Structure, function and maintenance standard SEN00523-00
2. When turning
• When steering unit (7) is actuated, the oil sent • The oil at the steering cylinder head end goes
from port (P) of priority valve (2) passes through out from suction valve (5). It then goes from port
ports (P) and (L) of steering unit (7) and enters (CR) of directional valve (6) through check valve
port (L) of directional valve (6). (4) and is drained to the hydraulic tank from port
At the same time, oil from priority valve (2) also (HT) of the flow amp valve.
enters chamber (M) of pressure control valve • If there are rocks on the road or the the road sur-
(3). face is uneven, and any abnormal external force
• When the oil entering directional valve (6) rises is applied to the tires and steering cylinder, relief
to a pressure greater than the force of the valves (8) and (9) of suction valve (5) open at a
spring, it pushes the spool to the right, and en- pressure of 29.1 MPa {285.5 kg/cm2}, so the oil
ters chamber (C) of pressure control valve (3). passes through directional valve (6) and is
When it rises to a pressure greater than the drained to the hydraulic tank.
force of the spring in chamber (C) also, it push-
es the spool to the left.
• The oil that is already in chamber (M) of pres-
sure control valve (3) enters chamber (N) when
the spool is pushed to the left by the action of
steering unit (7). It then flows from port (P), goes
out from port (CL) of directional valve (6), and
flows from suction valve (5) to the bottom end of
the steering cylinder.
HM400-2 7
SEN00523-00 10 Structure, function and maintenance standard
Steering valve 1
8 HM400-2
10 Structure, function and maintenance standard SEN00523-00
Outline Structure
• The orbit-roll valve is connected directly to the • Spool (9) is connected to the drive shaft of the
steering wheel shaft. If the steering wheel is op- steering wheel, and is connected to sleeve (8)
erated, the orbit-roll valve operates the steering by center pin (7) (this is not touching the spool
valve by using the oil from the PPC pump as the when the steering wheel is at the neutral posi-
pilot pressure. Then, the oil from the steering tion) and centering spring (2).
pump is sent to the right or left steering cylinder • Drive shaft (3) is meshed at the top with center
through the steering valve to change the travel pin (7) and forms one unit with sleeve (8). The
direction of the machine. bottom is meshed with the spline of rotor (5) of
• The orbit-roll valve, broadly speaking, consists the Gerotor set.
of the following components: rotary type spool • Valve body (4) has five ports. These are con-
(9) and sleeve (8), which have the function of se- nected to the pump circuit, tank circuit, steering
lecting the direction, and the Girotor set (a com- cylinder head end, bottom end, and flow amp
bination of rotor (5) and stator (10)), which acts valve pilot end. In addition, the port at the pump
as hydraulic motor during normal steering oper- end and the port at the tank end are connected
ations, and as a hand pump (in fact, the operat- by the check valve inside the body. If there is
ing force of the steering wheel is too high, so it any failure in the pump or engine, this check
cannot be operated) when the steering pump or valve acts to suck in oil directly from the tank.
engine have failed and the supply of oil is
stopped.
HM400-2 9
SEN00523-00 10 Structure, function and maintenance standard
10 HM400-2
10 Structure, function and maintenance standard SEN00523-00
HM400-2 11
SEN00523-00 10 Structure, function and maintenance standard
Steering cylinder 1
Unit: mm
No. Check item Criteria Remedy
12 HM400-2
SEN00523-00 10 Structure, function and maintenance standard
Hoist valve 1
14 HM400-2
10 Structure, function and maintenance standard SEN00523-00
1. Valve body
2. Hoist spool
3. Check valve
4. Housing
5. Relief valve
Unit: mm
No. Check item Criteria Remedy
HM400-2 15
SEN00523-00 10 Structure, function and maintenance standard
Operation
• The oil from the demand of valve enters port (C). • The ports to the hoist cylinder are blocked at
The passage to the hoist cylinder is blocked by both the bottom end and head end, so the hoist
hoist spool (2), so the oil is drained from tank (D) cylinder is held in position.
to the tank.
16 HM400-2
10 Structure, function and maintenance standard SEN00523-00
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
to the RAISE position, hoist spool (2) is moved end flows from port (B) to port (D), and flows to
to the left by the solenoid valve. the tank circuit.
• As a result, the oil flows from chamber (C),
opens check valve (3), and enters chamber (A).
• From chamber (A), the oil enters the bottom end
of the hoist cylinder, extends the hoist cylinder,
and raises the dump body.
HM400-2 17
SEN00523-00 10 Structure, function and maintenance standard
• When the hoist lever inside the cab is operated • The bottom end and head end of the hoist cylin-
to the FLOAT position, hoist spool (2) is moved der are connected inside the hoist valve, so the
to the right by the solenoid valve. As a result, hoist cylinder is placed in the free condition.
chamber (C) and chamber (D), and chamber (B)
and chamber (H) and chamber (D) are connect-
ed.
• The oil from the demand valve passes from
chamber (C) 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.
18 HM400-2
10 Structure, function and maintenance standard SEN00523-00
• When the hoist lever inside the cab is operated • At the same time, the return oil from the head
from the FLOAT position to the LOWER position, end of the hoist cylinder flows from chamber (A)
hoist spool (2) is moved further to the right from to chamber (H).
the FLOAT position by the solenoid valve. As a • When the dump body is lowered, the output
result, the oil flows from chamber (C), pushes pressure of the solenoid valve rises and be-
open check valve (3), and enters chamber (B). comes greater than the cracking pressure of the
• The oil from chamber (B) enters the head end of pilot check valve. As a result, the return oil from
the hoist cylinder, retracts the cylinder, and low- chamber (H) returns to the tank through two
ers the dump body. lines: one from chamber (D) to the tank, and the
other from chamber (E) to the tank.
HM400-2 19
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EPC valve 1
20 HM400-2
10 Structure, function and maintenance standard SEN00523-00
HM400-2 21
SEN00523-00 10 Structure, function and maintenance standard
22 HM400-2
10 Structure, function and maintenance standard SEN00523-00
Hoist cylinder 1
Unit: mm
No. Check item Criteria Remedy
HM400-2 23
SEN00523-00 10 Structure, function and maintenance standard
Hydraulic pump 1
Steering, hoist control pump
SDR(30)100+100+SB(1)8
Unit: mm
No. Check item Criteria Remedy
Model Standard clearance Clearance limit
SDR(30)-100
1 Side clearance 0.16 – 0.20 0.24
SDR(30)-100
SB(1)-8 0.10 – 0.15 0.19
Clearance between inside SDR(30)-100
diameter of plain bearing and 0.06 – 0.13 0.20
2 SDR(30)-100 Replace
outside of diameter of gear
shaft SB(1)-8 0.06 – 0.12 0.20
Model Standard size Tolerance Repair limit
SDR(30)-100 0
3 Depth for knocking in pin 10
SDR(30)-100 -0.5 –
SB(1)-8 9.2 ±0.3
4 Rotating torque of spline shaft 8.7 – 20.7 Nm {0.9 – 2.1 kgm}
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
Discharge amount (rpm) (l/min) –
– Oil: EO10-CD (kg/cm2)} (l/min)
Oil temperature: 45–55°C SDR(30)-100
20.6 231 213.4
SDR(30)-100 2,500
{210}
SB(1)-8 17.2 15.8
24 HM400-2
10 Structure, function and maintenance standard SEN00523-00
Power train, front brake cooling, differential lock pump (Machine with differential lock differential)
SDR(30)80+SB(1)12+8
Unit: mm
No. Check item Criteria Remedy
Model Standard clearance Clearance limit
SDR(30)-80 0.16 – 0.20 0.24
1 Side clearance
SB(1)-12
0.10 – 0.15 0.19
SB(1)-8
Clearance between inside SDR(30)-80 0.06 – 0.13
diameter of plain bearing and
2 SB(1)-12 0.20 Replace
outside of diameter of gear 0.06 – 0.12
shaft SB(1)-8
Model Standard size Tolerance Repair limit
3
SDR(30)-80 0
Depth for knocking in pin 10
4 SB(1)-12 -0.5 –
5 SB(1)-8 9.2 ±0.3
6 Rotating torque of spline shaft 10.8 – 21.5 Nm {1.1 – 2.2 kgm}
Delivery Standard
Rotating Delivery
pressure delivery
Model speed amount limit
{MPa amount
Discharge amount (rpm) (l/min) –
(kg/cm2)} (l/min)
– Oil: EO10-CD
Oil temperature: 45–55°C SDR(30)-80 184.5 170.4
20.6
SB(1)-12 2,500 26.7 24.5
{210}
SB(1)-8 17.2 15.8
HM400-2 25
SEN00523-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
26 HM400-2
10 Structure, function and maintenance standard SEN00523-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 27
SEN00523-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
28 HM400-2
10 Structure, function and maintenance standard SEN00523-00
Unit: mm
No. Check item Criteria Remedy
HM400-2 29
SEN00523-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
30 HM400-2
SEN00524-00
HM400-2
HM400-2 1
SEN00524-00 10 Structure, function and maintenance standard
2 HM400-2
10 Structure, function and maintenance standard SEN00524-00
Air conditioner 1
HM400-2 3
SEN00524-00 10 Structure, function and maintenance standard
4 HM400-2
10 Structure, function and maintenance standard SEN00524-00
HM400-2 5
SEN00524-00 10 Structure, function and maintenance standard
Receiver dryer
1. Pressure switch
2. Label
6 HM400-2
10 Structure, function and maintenance standard SEN00524-00
Condenser
1. Fin
2. Tube
HM400-2 7
SEN00524-00 10 Structure, function and maintenance standard
Compressor
1. Case
2. Clutch
8 HM400-2
SEN00524-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
10 HM400-2
SEN00525-00
HM400-2 1
SEN00525-00 10 Structure, function and maintenance standard
Network data
1. From machine monitor to each controller
• Switch sensor data
• Option setting data
• Model selection data
2. From each controller to machine monitor
• Display data related to each controller
• Service mode data
• Troubleshooting data
2 HM400-2
10 Structure, function and maintenance standard SEN00525-00
Outline
The machine monitor system is comprised of 1. Displaying trouble history data for electrical
controllers and a machine monitor. The control- components
lers on the network use the data from the sen- • Displays electrical component failure
sors installed to all parts of the machine to occurrence data from each controller
observe and control the condition of the vehicle that is saved in machine monitor
and transmit those data as network data to the • Deletes data from memory
machine monitor. The machine monitor, in 2. Displaying trouble history data for machine
return, displays these data and inform the oper- Displays machine failure occurrence data
ator of the condition of the machine. from each controller that is saved in machine
• There are two types of display on the machine monitor.
monitor: the normal mode and the service mode. 3. Real-time monitor
• The items that are always displayed for the op- Takes input, output signal, and calculation
erator are the normal mode items. Their main values recognized by each controller on
content is as follows. network and displays them in real time
1. Normal display items 4. Reduced cylinder mode
• Meters (speedometer, tachometer) This function is used to stop the supply of
• Gauges (engine coolant temperature, fuel sprayed from the fuel injector to each of
torque converter oil temperature, retard- the cylinders. This function is used for the
er oil temperature, fuel level) purpose of, for example, determining the
• Pilot display cylinder where there is defective combus-
• Service meter, odometer (character dis- tion.
play) 5. No injection cranking
2. Items displayed when there is abnormality This function is used to lubricate an engine
Caution, action code display (while an without starting the engine to drive a vehicle
action code is being displayed, press after a long-term storage.
machine monitor mode selector switch (>). 6. Adjusting function
A failure code (6-digit) is then displayed.) This function is used to correct installation
3. Maintenance monitor function errors of sensors, solenoid valves, and
When the filter, oil replacement interval is compensate production tolerances of parts
reached, the item needing replacement is and components. This function is also used
displayed in the character display. to change control characteristic data in
4. Others response to user's request.
In combination with the character display 7. Maintenance monitor
and the machine monitor mode selector This function is used to change filter oil
switch, which is used to operate the charac- replacement interval and stop the function.
ter display, the following items can be dis- 8. Operation information display function
played, set, and adjusted. This function is used to display fuel con-
1) Dozing counter (option) sumption amount per operation hour.
2) Display reverse travel distance mea- 9. Option selection function
surement value This function is used to select controller
3) Reset filter oil replacement interval information and optional equipment to be
4) Input telephone number operated.
5) Select language 10. Model selection function
Input model information to be mounted.
• To make it easier to carry out troubleshooting of 11. Initialize
the controllers on the network (including the This function is used to set the machine
monitor panel itself), a service mode function is monitor when the machine is shipped from
provided. Its main content is as follows. the factory.
HM400-2 3
SEN00525-00 10 Structure, function and maintenance standard
Machine monitor
4 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 5
SEN00525-00 10 Structure, function and maintenance standard
Related actuation A
Immediately
Display Display Display range/ Method of Central after
No. Device Color Alarm Remarks
item category conditions display warning starting
buzzer switch is
lamp
turned ON
Scale: 0 - 80 km/h or 0 - 50
White mph Analog
Meter Movement Background (mph display is only display
— — —
Travel color: Black when non-SI is used)
1
speed
Lights up
When side lamps light
Backlight LED Amber when — — Q
up
actuated
Scale:
0 - 3400 rpm (red
White, red Analog
Meter Movement Background zone: More than 2500 Q E —
display
Engine rpm)
2 color: Black
speed
Lights up
Backlight LED Amber When side lamps light when — — Q
up actuated
Scale:
50 - 150°C
White, red (red zone: Analog
Gauge Movement Background More than — — —
display
120°C)
color: Black
Brake
3 cooling Lights up
oil When temperature is
36 temperature Caution LED Red when Q E Q
more than 120°C
abnormal
Lights up
When side lamps light
Backlight LED Amber when — — Q
up
actuated
Scale:
50 - 135°C
White, red (red zone: Analog
Gauge Movement Background More than — — —
display
120°C)
color: Black
Torque
4 converter Lights up
When temperature is
37 oil Caution LED Red when Q E Q
temperature more than 120°C
abnormal
6 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 7
SEN00525-00 10 Structure, function and maintenance standard
8 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 9
SEN00525-00 10 Structure, function and maintenance standard
10 HM400-2
10 Structure, function and maintenance standard SEN00525-00
a On the service menu mode, the screen can be changed by pressing switches </>. Use these switches to
select the desired operation menu screen.
a While the following display screen (selection screen) is being displayed, the screen can be changed to the
menu screen/operation screen of each function by pressing switch U.
a While the following display screen (selection screen) is being displayed, the screen can be changed to the
service meter screen of each function by pressing switch t.
** indicates the number of currently memorized ** indicates the number of currently memorized
failure histories. failure histories.
(Up to max. 20 failure histories can be memo- (Up to max. 20 failure histories can be memo-
rized.) rized.)
Outline Outline
Use this function to check the electric system failure Use this function to check the machine system fail-
history of respective controllers being memorized ure history of respective controllers being memo-
by the machine monitor. Regarding the error code rized by the machine monitor. Regarding the error
being used in the electric equipment system failure code being used in the machine system failure his-
history, refer to the Chapter "Troubleshooting". tory, refer to the Chapter "Troubleshooting".
When the fault is repaired and after checking and
confirming that normal operation has been restored,
delete the fault history.
HM400-2 11
SEN00525-00 10 Structure, function and maintenance standard
Outline Outline
Use this function to check the inputting and output- Use this function to lubricate an engine without
ting signals being recognized by respective control- starting the engine to drive a vehicle after a long-
lers on the network. term storage.
Regarding the engine start method using this func-
4) Engine reduced cylinder function screen tion, refer to the Section "No injection cranking
operation of engine" in the chapter "Inspection and
Adjustment"
Outline
Use this function to cut off the supply of fuel sprayed
from the fuel injector to each of the cylinders in
order to determine the cylinder where there is
defective combustion. Outline
Regarding the inspection method using this func- Use this function to correct installation errors of sen-
tion, refer to the Section "Reduced cylinder mode sors, solenoid valves, and compensate production
operation of engine" in the chapter "Inspection and tolerances of parts and components. Use this func-
Adjustment" tion to change control characteristic data in
response to user's request.
Regarding the adjusting method using this function,
refer to the Section "Adjustment using monitor" in
the chapter "Inspection and Adjustment"
12 HM400-2
10 Structure, function and maintenance standard SEN00525-00
Outline
This function is being explained in the section "Filter
and oil changing time indication on the character
display" in the Chapter "Handling" in the Operation
and Maintenance Manual. Use this function to
change filter oil replacement interval and stop func-
tion.
Outline
Use this function to display fuel consumption
amount per operation hour.
Outline
This function operates on factory setting mode.
Since this function is for factory use only, do not
touch it.
HM400-2 13
SEN00525-00 10 Structure, function and maintenance standard
14 HM400-2
10 Structure, function and maintenance standard SEN00525-00
3) Selection of displaying the fault history of electric system and clearing the entire fault history of electric
system (second layer)
A current fault is displayed prior to the restored ones.
Pressing the > switch displays the next newer fault.
Pressing the < switch displays the next older fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the en-
tire fault history of electric system of the relevant controller.
Pressing the t switch changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the U switch changes the screen to the [Clear individually the fault history of electric system]
or [Clear the fault history of electric system] screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-out
clearing (but change the screen to that for individual clearing).
4) Clearing individually the fault history of electric system, and clearing the entire fault history of electric
system (the third layer)
Select YES or NO with the < or > switch.
Cursor (_) blinks on the selected item. Pressing the t switch changes the display as follows, with the
history reset if YES was selected, or not if NO was selected:
i) If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
ii) If YES (clear ) was selected, the display returns to the [Display the fault history of electric system]
screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the screen re-
turns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
HM400-2 15
SEN00525-00 10 Structure, function and maintenance standard
16 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 17
SEN00525-00 10 Structure, function and maintenance standard
Operation
1. Press the t switch and < switch for more than five seconds to go to the [ID Entry] screen.
2. Enter ID with the < and > switch, and press the U switch to go to the screen for service persons.
3. Press the < and > switch to display the [Select the real-time monitor] screen, then press the U switch to fix
the screen.
18 HM400-2
10 Structure, function and maintenance standard SEN00525-00
4. Press the switch U, and the [Monitor information display/selection] screen appears. Press the switch < and
the switch > to display the [Transmission controller information display/selection] screen, [Engine controller
information display/selection] screen, [Working equipment controller information display/selection] screen,
[VHMS controller information display/selection] screen and [2 item display function selection] screen in or-
der.
HM400-2 19
SEN00525-00 10 Structure, function and maintenance standard
5. Pressing the U switch, while each selection screen is shown, displays the [One-item display] screen or the
[Select information on 2-item display] screen.
In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the infor-
mation each controller has.
How to Enter an ID
After the screen was changed from another, “00000” is shown.
Enter a number 0-9 in the cursor position.
The cursor is at the highest digit first. Each time the < or > switch was pressed, the number changes by 1
within a range 0-9.
If the desired number was entered, press the U switch.
The cursor moves to the second highest digit. Repeat the procedures mentioned above until the last number
is filled in the lowest digit.
If the lowest digit was entered, press the U switch, and the screen changes to that for displaying/selecting the
second item. Alternately, pressing the t switch returns the screen to that for displaying/selecting two items.
In the case of 2-item display, enter the IDs of the information to be displayed, and the two items are shown
simultaneously. The IDs shown are the same as those on the 1-item display screen.
6. In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the
information each controller has.
20 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 21
SEN00525-00 10 Structure, function and maintenance standard
Transmission controller
22 HM400-2
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HM400-2 23
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Retarder controller
24 HM400-2
10 Structure, function and maintenance standard SEN00525-00
Engine controller
HM400-2 25
SEN00525-00 10 Structure, function and maintenance standard
26 HM400-2
SEN00525-00 10 Structure, function and maintenance standard
1 Monitor software part number 20200 VERSION Software part number is displayed
8 Brake oil temperature F 30202 BRAKE OIL TF Brake oil temperature is displayed
Brake oil temperature F 30205 BRAKE OIL TF Brake oil temperature is displayed
Brake oil temperature M 30201 BRAKE OIL TM Brake oil temperature is displayed
Brake oil temperature M 30204 BRAKE OIL TM Brake oil temperature is displayed
9
Brake oil temperature R 30203 BRAKE OIL TR Brake oil temperature is displayed
Brake oil temperature R 30206 BRAKE OIL TR Brake oil temperature is displayed
11 Dip SW position 30205 SW5-1, SW5-2 SW5-1: SI spec, Non-SI spec selection
SW5-2: Not used
28 HM400-2
10 Structure, function and maintenance standard SEN00525-00
0 – 85 z
(120°C): 1.62 V
(80°C): 2.91 V
(120°C): 1.62 V
(80°C): 2.91 V
(120°C): 1.62 V
(80°C): 2.91 V
0 – 30 V
— Not used
SW5-1:
Constantly OFF for 7831-46-300*
Constantly OFF for 7831-46-400*
SW5-2: Not used
— Not used
— Not used
— Not used
HM400-2 29
SEN00525-00 10 Structure, function and maintenance standard
30 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 31
SEN00525-00 10 Structure, function and maintenance standard
2. Enter ID with the < and > switch, and press the U switch to go to the screen for service persons.
3. Press the < and > switch to display the [Select the cylinder cut-out mode] screen, then press the U switch
to fix the screen.
32 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 33
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34 HM400-2
10 Structure, function and maintenance standard SEN00525-00
Adjusting function
Regarding the adjusting method using this function,
refer to the Section "Adjustment using monitor" in
the chapter "Inspection and Adjustment"
This section will describe the operation method
only.
HM400-2 35
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36 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 37
SEN00525-00 10 Structure, function and maintenance standard
• Press the <> SW to select YES/NO. • Set the timer to stop/ release from stop for each
• The cursor (_) blinks on the selected item. of the maintenance items.
When YES is selected, pressing the t SW ac-
cepts the change. When NO is selected, press- • When the timer is made enables after it was
ing the t SW cancels the change, and goes to stopped, the interval time set to the timer before
the "maintenance item selection" screen. the timer was disabled is restored.
a The cursor is positioned at NO by default to pre- a The remaining time on the timer is reset.
vent from mistakenly carrying out the reset oper- a The number of reset times is not incremented
ation. but remains the same.
38 HM400-2
10 Structure, function and maintenance standard SEN00525-00
*1. Press the U SW to change the screen to the "All item timer stop" screen.
*2. In the case that "All item timer stop" is selected
*3. When all item stop is carried out:
The timer functions for all items are disabled, and the screen returns to the "Maintenance monitor selec-
tion" screen.
When the specific item is carried out, the setting is made to disable the function.
When cancel is carried out:
The operation is cancelled and the screen returns to the "maintenance selection" screen.
*4. When "All item valid" is selected
*5. Press the <> SW to select YES/NO.
The cursor (_) blinks on the selected item
a The cursor is positioned at NO (not change) by default to prevent from mistakenly carrying out the reset
operation.
*6. When all item valid is carried out:
Regardless of whether specific item is valid or invalid, the interval time set to the timer before the timer
was disabled is effective for all items.
The remaining time on the timer is reset.
Meanwhile, the number of reset times is not incremented but remains the same.
The screen returns to the "maintenance monitor selection" screen.
Setting is made valid for each item.
When cancel is carried out:
The operation is cancelled and the screen returns to the "maintenance selection" screen.
HM400-2 39
SEN00525-00 10 Structure, function and maintenance standard
English message
No. Item Interval [h] ID number
[11 one-byte characters]
1 Pre fuel filter 500 P FUEL FILT 41
2 Engine oil 500 ENG OIL 01
3 Engine oil filter 500 ENG FILT 02
4 Transmission oil 1,000 TM OIL 12
5 Transmission oil filter 1,000 TM FILT 13
6 Fuel filter 1,000 FUEL FILT 03
7 Corrosion resistor 1,000 CORR RES 06
8 Brake oil 1,000 BK OIL 17
9 Brake oil filter 1,000 BK OIL FILT 14
10 Brake cooling oil filter 1,000 BK C FILT 16
11 Hydraulic oil filter 2,000 HYD FILT 04
12 Diff case oil 2,000 DIFF OIL 11
13 Final drive oil 2,000 FNL OIL 08
14 Hydraulic oil 4,000 HYD OIL 10
40 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HM400-2 41
SEN00525-00 10 Structure, function and maintenance standard
42 HM400-2
SEN00525-00 10 Structure, function and maintenance standard
1 CN1 1 — — —
8 CN1 8 — — —
9 CN1 9 — — GND
10 CN1 10 — — GND
17 CN1 17 — — GND
18 CN1 18 — — GND
19 CN1 19 — — GND
20 CN1 20 — — GND
*1: NSW +24V input port is active even if the setting is made to KEY OFF when power is supplied directly from
battery.
44 HM400-2
10 Structure, function and maintenance standard SEN00525-00
HI BEAM Q Q Q
AISS SW Q Q Q
PASSING SW Q Q Q
RIGHT TURN Q Q Q
HM400-2 45
SEN00525-00 10 Structure, function and maintenance standard
29 CN2A 9 — — GND
38 CN2A 18 I A A_IN_0 (0 – 30 V)
44 CN2B 6 — — GND
50 CN2B 12 I A A_IN_1 (0 – 30 V)
*1: NSW +24V input port is active even if the setting is made to KEY OFF when power is supplied directly from
battery.
*2: Setting is made to PULL UP.
46 HM400-2
10 Structure, function and maintenance standard SEN00525-00
ENGINE MODE SW Q Q Q
LEFT TURN Q Q Q
SENSOR GND Q Q Q
SEAT BELT Q Q Q
LR DIFF LOCK FOOT SW Q Q Q Left and right differential lock foot switch
LR DIFF LOCK SW1 Q Q Q Left and right differential lock 3 position switch
LR DIFF LOCK SW2 Q Q Q Left and right differential lock 3 position switch
HM400-2 47
SEN00525-00 10 Structure, function and maintenance standard
59 CN3A 9 — — GND
62 CN3A 12 I D NC
68 CN3A 18 — — NC
72 CN3B 4 I A A_IN_8 (0 – 5 V)
73 CN3B 5 I A A_IN_10 (0 – 5 V)
74 CN3B 6 — — SGND
77 CN3B 9 I A A_IN_7 (0 – 5 V)
78 CN3B 10 I A A_IN_9 (0 – 5 V)
79 CN3B 11 — — GND
80 CN3B 12 — — NC
48 HM400-2
10 Structure, function and maintenance standard SEN00525-00
GND Q Q Q GND
ANALOG GND Q Q Q
CAN (+) Q Q Q
HM400-2 49
SEN00525-00 10 Structure, function and maintenance standard
86 CN4 6 — — GND
87 CN4 7 — — GND
89 CN4 9 — — NC
90 CN4 10 — — NC
91 CN4 11 — — NC
92 CN4 12 — — NC
93 CN5 1 — — NC
94 CN5 2 — — RS232C_1_RTS
95 CN5 3 — — RS232C_1_RD
96 CN5 4 — — RS232C_2_RD
97 CN5 5 — — RS232C_2_RTS
98 CN5 6 — — NC
99 CN5 7 — — NC
106 CN5 14 — — NC
110 CN6 4 — — NC
111 CN6 5 — — Flash writing date (receiving)
112 CN6 6 — — NC
50 HM400-2
10 Structure, function and maintenance standard SEN00525-00
CAN (–) Q Q Q
RS232C-TXD Q Q Q
FLASH SW Q Q Q
RS232C-RXD Q Q Q
SIGNAL GND Q Q Q
HM400-2 51
SEN00525-00 10 Structure, function and maintenance standard
2 SW1 1 I D
3 SW1 2 I D
4 SW1 3 I D
5 SW1 4 I D
6 SW1 5 I D
7 SW1 6 I D
8 SW1 7 I D
9 SW1 8 I D
10 SW1 9 I D
11 SW1 A I D
12 SW1 B I D
13 SW1 C I D
14 SW1 D I D
15 SW1 E I D
16 SW1 F I D
18 SW2 1 I D
19 SW2 2 I D
20 SW2 3 I D
21 SW2 4 I D
22 SW2 5 I D
23 SW2 6 I D
24 SW2 7 I D
25 SW2 8 I D
26 SW2 9 I D
27 SW2 A I D
28 SW2 B I D
29 SW2 C I D
30 SW2 D I D
31 SW2 E I D
32 SW2 F I D
52 HM400-2
10 Structure, function and maintenance standard SEN00525-00
Model name
Signal name Remarks
HM300 HM350 HM400
— Q Q Q Reserved
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q Reserved
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
HM400-2 53
SEN00525-00 10 Structure, function and maintenance standard
34 SW3 1 I D
35 SW3 2 I D
36 SW3 3 I D
37 SW3 4 I D
38 SW3 5 I D
39 SW3 6 I D
40 SW3 7 I D
41 SW3 8 I D
42 SW3 9 I D
43 SW3 A I D
44 SW3 B I D
45 SW3 C I D
46 SW3 D I D
47 SW3 E I D
48 SW3 F I D
51 SW5 3 I D
52 SW5 4 I D
53 SW6 1 I D
54 SW6 2 I D
55 SW6 3 I D
56 SW6 4 I D
54 HM400-2
10 Structure, function and maintenance standard SEN00525-00
Model name
Signal name Remarks
HM300 HM350 HM400
— Q Q Q Reserved
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q Reserved
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
— Q Q Q
HM400-2 55
SEN00525-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
56 HM400-2
SEN00526-00
HM400-2 1
SEN00526-00 10 Structure, function and maintenance standard
2 HM400-2
10 Structure, function and maintenance standard SEN00526-00
HM400-2 3
SEN00526-00 10 Structure, function and maintenance standard
Data item received from the transmission con- RPC-k (irregularly updated)
troller to the network.
No. Item
1 Model selection information
RTCDB1 (Updated for 10 msec.)
2 Option selection information
No. Item [Option item]
1 Engine speed a. Maximum gear speed setting
2 Accelerator opening b. Maximum gear speed setting for the Body-up state
c. Exhaust brake equipped/ not equipped
3 Seat unoccupied judgment
d. Accelerator linked retarder provided/not provided
4 Reverse not-permitted command e. Maintenance sensor provided/not provided
5 Retarder SW (front) condition f. Parking brake interlock provided/not provided
6 Retarder SW (rear) condition g. Economy output change function E1/E2
4 HM400-2
10 Structure, function and maintenance standard SEN00526-00
Transmission controller
Outline
• The transmission controller controls the trans- 7. It connects to the network and shares vari-
mission system. ous data with other controllers.
It has the following features and functions. 8. It receives the model selection data (what
1. It has a power mode and an economy mode, model it is mounted on) through the net-
and the gearshifting pattern can be select- work.
ed. 9. It has a self-diagnostic function which di-
2. The braking mode is the mode when the vides the input and output systems further
brake is used. By raising the gearshifting into small parts.
point and increasing the speed of the brake 10. The self-diagnostic function is displayed on
cooling pump it is possible to raise the cool- the monitor.
ing effect of the retarder and make effective 11. When an abnormality is detected, it trans-
use of the engine brake. mits the details to the network.
3. It controls the brake through the retarder 12. It uses the machine monitor to display if the
controller for the torque converter lock-up failure is still existing.
solenoid valve and overrun prevention. 13. It provides an escape function for use when
4. It controls the inter-axle differential lock so- there is a failure in the electrical system.
lenoid valve.
5. To reduce the shock when shifting gear, it
outputs the throttle correction command to
the engine controller when shifting gear and
adjusts the engine speed.
6. Speed sensors are installed at three places
(transmission input shaft, intermediate
shaft, and output shaft). This makes it pos-
sible to detect slippage of the transmission
clutches and to protect the transmission
when there is any abnormality in the hydrau-
lic system.
HM400-2 5
SEN00526-00 10 Structure, function and maintenance standard
ATC2
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Output 21 Input/output
2 Input 22 Network Low Input/output
3 Engine oil filter condition (if equipped) Input 23 Input/output
4 Input 24 Input
5 Shift lever position 5 Input 25 Shift lever position R1 Input
6 Shift lever position 1 Input 26 Shift lever position 3 Input
7 Emergency escape switch Input 27 Input
8 Output 28 Input
9 Output 29 GND (for output shaft rotation input, differential gear rotation) —
10 T/M output rotation sensor Input 30 T/M output shaft rotation Input
11 Output 31 —
12 — 32 Network High Input/output
13 Engine oil level Input 33 Input/output
14 Output 34 —
15 Shift lever position D Input 35 Shift lever position R2 Input
16 Shift lever position 2 Input 36 Shift lever position 4 Input
17 Input 37 T/M oil filter condition Input
18 Output 38 Input
19 Output 39 GND (for input shaft rotation input, intermediate shaft rotation input) —
20 T/M intermediate shaft rotation Input 40 T/M input shaft rotation Input
ATC3
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Power supply 24V Input 21 GND Input
2 Proportional solenoid power supply 24V Input 22 Proportional solenoid power voltage 24V Input
3 ECM output Low, 2 nd, Hoist, Eps, Kichou (-) Input 23 ECM Rev, 3 rd, lock-up, Inter-axle differential lock (-) Input
4 Output 24 Key SW ACC Input
5 ECMV 2nd (+) Output 25 ECMV Rev (+) Output
6 ECMV lock-up Output 26 ECMV Hig (+) Output
7 Output 27 Output
8 Torque converter oil pressure sensor power supply (24V) Output 28 Hoist EPC valve Output
9 Fill switch 2nd Input 29 Fill switch Rev Input
10 Input 30 Fill switch High Input
11 Power supply 24V Input 31 GND Input
12 Proportional solenoid power supply 24V Input 32 GND Input
13 ECMV output High, 1 st, Hoist, Change (-) Input 33 GND Input
14 Key SW ACC Input 34 —
15 ECMV 3rd (+) Output 35 ECMV inter-axle differential lock (+) Output
16 ECMV Low (+) Output 36 ECMV 1st (+) Output
17 Hoist switchover valve Output 37 Output
18 Output 38 Kick-out solenoid (hoist) Output
19 Fill switch 3 rd Input 39 Input
20 Fill switch Low Input 40 Fill switch 1 st Input
6 HM400-2
10 Structure, function and maintenance standard SEN00526-00
Economy mode:
When the machine is being used under light load,
such as when traveling unloaded or on flat ground,
the shift-up point and shift-down point are both low-
ered, the engine speed is maintained at a lower level,
and the fuel consumption, noise, and transmission
shock are improved. In this mode, the maximum en-
gine output is limited.
HM400-2 7
SEN00526-00 10 Structure, function and maintenance standard
8 HM400-2
10 Structure, function and maintenance standard SEN00526-00
5. The auto brake ON point when traveling in F6 is If the operation is not correct, gearshifting is
2,400 rpm. restricted. (By default, the transmission shifts to
R2. The transmission is set to R1 by making
Gearshift lever positions and method of shifting the selection setting on the machine monitor.)
1) Gearshift lever position D 4) Gearshift lever position N
When shifting up (in power mode) At the neutral position, none of the transmission
I) When the gearshift lever is set at position D, the clutches are actuated.
transmission is set to F2 torque converter
range. Shift hold function
II) When the accelerator pedal is depressed, the • If the hold switch on the gearshift lever is pushed
engine speed rises and accelerates. When the once, the current gear speed is held. If the hold
transmission input shaft speed reaches 1050 - switch is pressed once again or the gearshift le-
1,400 rpm, the lock-up clutch is engaged, so the ver is operated, the gear speed can be changed.
torque converter is directly engaged and the If the travel speed lowers excessively while the
transmission is set to direct travel. gear speed is held, the gear is shifted down.
III) As the engine speed rises further and reaches When the travel speed rises again, however, the
1,730 - 2,090 rpm, the transmission shifts up to original gear speed is held.
F3.
While the transmission is shifting up, the engine Time when gear cannot be shifted
speed is also lowered (a command is output to • In the automatic shift range, to prevent mistaken
the engine controller) in order to reduce the operation caused by excessive variation in the
shock when shifting gear. speed when shifting gear, a time delay is used to
IV) Immediately after shifting up, the engine speed prevent the gears from being shifted within the
momentarily goes down, but as the machine set time.
accelerates, it rises again and the transmission • The gearshifting time delay is controlled precise-
shifts up in turn to F4 to F6 in the same way as ly by each gearshifting pattern through the use
in III) above. of the all-range electronic modulation system.
When shifting down (in power mode) The approximate values for the gearshifting pat-
I) When the load increases and the engine speed tern and gearshifting time delay are shown in
drops to 1,030 - 1,300 rpm, the transmission the diagram below.
shifts down one speed.
(For example, when traveling in F6, the trans-
mission shifts down to F5.)
While the transmission is shifting up, the engine
speed is also raised (a command is output to
the engine controller) in order to reduce the
shock when shifting gear.
II) As the engine speed goes down further and the
transmission shifts down in turn to F2, the
torque converter lock-up clutch is disengaged
and the transmission enters the torque con-
verter drive.
HM400-2 9
SEN00526-00 10 Structure, function and maintenance standard
Parking brake interlock function (option) When traveling forward at a speed of more than
Functional outline 1.9 km/h, even if the gearshift lever is operated
When the parking brake interlock function is actu- to positions R1 or R2, the transmission will not
ated, the speed range is shifted to the neutral posi- be shifted immediately to travel in reverse. The
tion regardless of the gearshift lever position. speed range is shifted to N and the engine
This function is actuated only when the optional speed is lowered to reduce the travel speed.
equipment is provided. When the travel speed goes below 1.9 km/h,
the transmission is shifted to REVERSE.
Actuation condition:
Parking brake = ON When traveling in reverse at a speed of more
than 7.2 km/h with the gearshift lever at position
Release condition: R2, even if the gearshift lever is operated from
1. Parking brake = OFF and the shift lever position R2 to R1, the transmission does not shift to R1.
2. Parking brake = ON, the engine speed is more When the travel speed goes below 1.9 km/h,
than 500 rpm, and the gearshift lever is operated the transmission is shifted to R1.
N o D o N o D o N o D o N within five sec-
onds When starting the engine, if the machine is
already traveling forward or in reverse at a
a For the purpose of, for example, the inspection, speed of more than 3.8 km/h, even if the gear-
to shift the speed range to a position other than shift lever is operated to a position other than N,
N with the parking brake applied the parking the machine will not move and the transmission
brake, interlock is released in the same way as will be held at N.
in the release condition 2. When the travel speed goes below 3.8 km/h, it
is permitted to move the machine off.
Safety functions (To prevent overload on power train, to improve
1) Down-shift inhibitor function durability and reliability)
If gearshift lever is operated D o 5 - 1, 5 o 4 - 4) Power train overrun prevention rear brake func-
1, 4 o 3 - 1, 3 o 2 -1, 2 o 1 tion
For example, when traveling in D (F6), even if If the engine speed rises to more than 2,400
the gearshift lever is operated to 4, the trans- rpm (more than 2,350 rpm in F6), the central
mission does not shift directly F6 o F4. It shifts warning lamp flashes and the alarm buzzer
down F6 o F5 o F4 in turn according to the sounds.
travel speed. If the engine speed rises to more than 2,450
(Even if the operator makes a mistake in opera- rpm (more than 2,400 rpm in F6), the rear brake
tion of the gearshift lever, the transmission does is automatically actuated.
not skip a gear speed. This is to prevent over- (To prevent overrun of engine, torque converter,
running of the engine.) and transmission, to improve durability and reli-
2) Neutral safety function ability)
This circuit prevents the engine from starting if 5) REVERSE safety
the gearshift lever is not at the N position, even The machine will not travel in reverse if the
if the starting switch is turned to the START dump control lever is not at FLOAT and the
position. dump body is not completely lowered.
(This is a safety circuit to prevent the machine (Turnover prevention function)
from moving unexpectedly when the engine is However, if the gearshift lever is at the R1 posi-
started.) tion and the shift hold switch is pressed, it is
3) Directional inhibit function possible to travel in reverse while the switch
When traveling in reverse at a speed of more being pressed, even if the dump body is not
than 2.0 km/h, even if the gearshift lever is fully lowered.
operated to D or positions 5 to 1, the transmis- 6) Speed range limit function when dump body is
sion will not be shifted immediately to travel for- raised
ward. The engine speed is lowered to reduce After dumping the load, if the body is not com-
the travel speed, and when the travel speed pletely lowered, shifting up is limited.
goes below 3.8 km/h, the transmission is shifted If the gearshift lever is at D, the machine starts
to FORWARD. in F2. If the former is at positions 5 to 1, the lat-
(To prevent overload on power train, to improve ter starts in F1. The gear is not shifted up until
durability and reliability) the body is completely lowered.
10 HM400-2
10 Structure, function and maintenance standard SEN00526-00
Self-diagnostic function
• The controller carries out self-diagnosis of the
system and displays any abnormalities.
• The details of the self-diagnosis are displayed
on a monitor.
• If any abnormality is detected by the self-diagno-
sis function, the abnormality data is transmitted
to the network and is displayed as an action
code on the machine monitor. The transmission
system caution, warning lamp, or alarm buzzer
may also be actuated.
HM400-2 11
SEN00526-00 10 Structure, function and maintenance standard
1 Software part number 20201 VERSION Mass production software part number is output
2 Application version 20223 VERSION (APP) Software version is output (Soft logic part version)
3 Data version 20224 VERSION (DATA) Software version is output (Soft logic part version)
4 T/M input axis rotation 31200 T/M SPEED:IN Input axis rotation speed is output
5 T/M intermediate axis 31300 T/M SPEED:MID Intermediate axis rotation speed is output
rotation
6 T/M output axis rotation 31400 T/M SPEED:OUT Output axis rotation speed is output
7 T/M differential axis 31402 T/M DIFF OUT Differential axis rotation speed is output
rotation
9 T/C oil temperature 30100 T/C OIL TEMP T/C oil temperature (A_IN_1) of oil temperature value is
output
10 T/C oil temperature 30101 T/C OIL TEMP T/C oil temperature (A_IN_1) of search voltage value is
output
11 T/M oil temperature 32500 T/M OIL TEMP T/M oil temperature of oil temperature value is output
12 HM400-2
10 Structure, function and maintenance standard SEN00526-00
0: OFF
1: ON
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20V = 100°C
1.61 V = 120°C
HM400-2 13
SEN00526-00 10 Structure, function and maintenance standard
12 T/M oil temperature 32501 T/M OIL TEMP T/M oil temperature of search voltage value is output
13 S/T oil temperature 32701 STRG OIL TEMP S/T oil temperature (A_IN_4) of oil temperature value is
output
14 S/T oil temperature 32702 STRG OIL TEMP S/T oil temperature (A_IN_4) of search voltage value is
output
15 T/C oil temperature 32600 T/C OIL PRESS T/C oil temperature (A_IN_3) of pressure ratio voltage
value is output
16 T/C oil temperature 32605 T/C OIL PRESS T/C oil temperature (A_IN_3) of input voltage value is
output
17 Clutch FILL SW 38921 FILL HLR123 Every each clutch of FILL SW recognition condition is
output
18 Solenoid output (H) 31600 ECMV H DIR HIGH clutch of ECMV output direction current is output
14 HM400-2
10 Structure, function and maintenance standard SEN00526-00
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
4.72 V = 0°C
4.33 V = 30°C
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
[1 (ON), 0 (OFF)] by data to support right under HLR123 I H: H Fill SW recognition [1:ON, 0:OFF]
000000: N time
100010: F4 time
HM400-2 15
SEN00526-00 10 Structure, function and maintenance standard
19 Solenoid output (L) 31601 ECMV L DIR LOW clutch of ECMV output direction current is output
20 Solenoid output (1st) 31602 ECMV 1 DIR 1st clutch of ECMV output direction current is output
21 Solenoid output (2nd) 31603 ECMV 2 DIR 2nd clutch of ECMV output direction current is output
22 Solenoid output (3rd) 31604 ECMV 3 DIR 3rd clutch of ECMV output direction current is output
23 Solenoid output (R) 31606 ECMV R DIR REV clutch of ECMV output direction current is output
24 Solenoid output (L/U) 31609 ECMV LU DIR L/U clutch of ECMV output direction current is output
25 Solenoid output (DIFF) 31607 ECMV D DIR Differential of ECMV output direction current is output
26 Angle sensor 32900 ANGLE SENSOR Angle sensor input (A_IN_8) of angle sensor ratio value
is output
27 Angle sensor 32902 ANGLE SENSOR Angle sensor input (A_IN_8) of voltage value is output
30 Throttle modified value 36000 THROTTLE MOD Throttle modified value is output sent to engine controller
16 HM400-2
10 Structure, function and maintenance standard SEN00526-00
69
x1 [° ] (-25.0 – +25.0 [° ])
HM400-2 17
SEN00526-00 10 Structure, function and maintenance standard
potentiometer 1
potentiometer 2
(Hi)
(Lo)
calibration value ( )
calibration value ( )
18 HM400-2
10 Structure, function and maintenance standard SEN00526-00
0: Except seating
1: Seating
HM400-2 19
SEN00526-00 10 Structure, function and maintenance standard
42 Low clutch trigger 38900 TRIGGER MOD L Low clutch trigger compensation value is output (all oil
43 High clutch trigger 38901 TRIGGER MOD H High clutch trigger compensation value is output (all oil
20 HM400-2
10 Structure, function and maintenance standard SEN00526-00
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM400-2 21
SEN00526-00 10 Structure, function and maintenance standard
44 1st clutch trigger 38902 TRIGGER MOD 1 1st clutch trigger compensation value is output (all oil
45 2nd clutch trigger 38903 TRIGGER MOD 2 2nd clutch trigger compensation value (all oil pressure
22 HM400-2
10 Structure, function and maintenance standard SEN00526-00
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM400-2 23
SEN00526-00 10 Structure, function and maintenance standard
46 3rd clutch trigger 38904 TRIGGER MOD 3 3rd clutch trigger compensation value (all oil pressure
47 Revolution clutch trigger 38906 TRIGGER MOD R Revolution clutch trigger compensation value (all oil
24 HM400-2
10 Structure, function and maintenance standard SEN00526-00
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
AABBCCDD
7F=127 (MAX)
01=1
00=0
FF=-1
FE=-2
80=-128 (MIN)
HM400-2 25
SEN00526-00 10 Structure, function and maintenance standard
48 Trigger initial learning flag 38922 TRIG HLR123 Output an early condition of learning flag state of trigger
time every each clutch
[H, L, R, 1, 2, 3]
49 Fill time (L) 41800 FILL TIME L LOW clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
50 Fill time (H) 41801 FILL TIME H HIGH clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
51 Fill time (1) 41802 FILL TIME 1 1st clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
52 Fill time (2) 41803 FILL TIME 2 2nd clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
53 Fill time (3) 41804 FILL TIME 3 3rd clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
54 Fill time (R) 41806 FILL TIME R REV clutch fill time value is output
(condition at the time of gearing just before that)
x10 [msec] (0 – 2.55 [sec], No fill :0)
55 Throttle lower limit value 44201 THROT LIMIT LO Throttle lower limit value output sent to engine controller
output x0.1 [%] (0 – +100.0 [%])
56 Throttle higher limit value 44200 THROT LIMIT HI Throttle higher limit value output sent to engine controller
output x0.1 [%] (0 – +100.0 [%])
26 HM400-2
10 Structure, function and maintenance standard SEN00526-00
HLR123
1111111 (Finished with all clutches learning)
HLR123
0000000 (Unlearned in all clutches)
HM400-2 27
SEN00526-00 10 Structure, function and maintenance standard
28 HM400-2
10 Structure, function and maintenance standard SEN00526-00
**0*****: Non-operation emergency steering (HM400) D_IN_2: Emergency steering relay 2 (HM400 only)
Example
01010000: F1 time
00001010: R2 time
00000000: N time
00100100: F6 time
HM400-2 29
SEN00526-00 10 Structure, function and maintenance standard
63 Output signal 40950 D-OUT-8-----15 Supports SOL_OUT_8, 9, 10A, 10B, 11A, 11B,
30 HM400-2
10 Structure, function and maintenance standard SEN00526-00
HM400-2 31
SEN00526-00 10 Structure, function and maintenance standard
32 HM400-2
10 Structure, function and maintenance standard SEN00526-00
HM400-2 33
SEN00526-00 10 Structure, function and maintenance standard
Retarder controller
Outline
The retarder controller has the following functions. 5. Transmission of network data
1. Retarder control 1) Retarder actuation, float caution, parking
The electromagnetic proportional valve for the brake actuation, exhaust brake actuation,
front and rear wheels is controlled according to inter-axle differential lock actuation, accu-
the operating angle of the retarder control lever mulator oil pressure drop warning, and other
and actuates the retarder brake. data are transmitted to the monitor panel.
2) The exhaust brake command, overrun pre-
2. Overrun prevention, retarder control when there vention, retarder command when there is
is transmission abuse abuse, and other data sent from the trans-
The electromagnetic proportional valve for the mission controller are received.
front and rear wheels is controlled based on the 3) The inter-axle differential lock actuation
command (Analog command) from the trans- command, reverse inhibit, and other data
mission controller and actuates the retarder are transmitted to the transmission control-
brake by a fixed amount. ler.
34 HM400-2
10 Structure, function and maintenance standard SEN00526-00
BRC2
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 Output 21 S-NET Input/output
2 Input 22 CAN0_L Input/output
3 Input 23 CAN1_L Input/output
4 232C R x D Input 24 FWE switch Input
5 Input 25 Input
6 Input 26 Input
7 Input 27 Input
8 Output 28 Input
9 Output 29 GND (pulse) —
10 Input 30 Input
11 Output 31 GND (S_NET GND) —
12 CAN_SH — 32 CAN0_H Input/output
13 Input 33 CAN1_H Input/output
14 232C T x D Output 34 GND (232C GND) —
15 Input 35 Key switch C (engine start) Input
16 Input 36 Input
17 Memory clear switch Input 37 Input
18 Output 38 Input
19 Output 39 GND (pulse) —
20 Input 40 Input
BRC3
Pin Input/output Pin Input/output
Signal name Signal name
No. signal No. signal
1 VB (controller PWR) Input 21 GND (controller GND) Input
2 VIS (solenoid PWR) Input 22 VIS (solenoid PWR) Input
3 SOL_COM (solenoid common GND) Input 23 SOL_COM (solenoid common GND) Input
4 Output 24 Key SIG Input
5 Output 25 Output
6 Retarder valve (front) Output 26 Output
7 Differential solenoid (front) Output 27 Brake cooling valve (front) Output
8 Output 28 Output
9 Parking brake pressure switch Input 29 Input
10 Differential pressure switch (front) Input 30 Input
11 VB (controller PWR) Input 31 GND (controller GND) Input
12 VIS (solenoid PWR) Input 32 GND (controller GND) Input
13 SOL_COM (solenoid common GND) Input 33 GND (controller GND) Input
14 Key SIG Input 34 Reservoir —
15 Output 35 Output
16 Retarder valve (rear) Output 36 Output
17 Differential solenoid (rear) Output 37 Brake cooling valve (rear) Output
18 Output 38 Output
19 Input 39 Input
20 Differential pressure switch (rear) Input 40 Input
HM400-2 35
SEN00526-00 10 Structure, function and maintenance standard
36 HM400-2
10 Structure, function and maintenance standard SEN00526-00
Relationship between retarder lever potentiometer and output to electromagnetic proportional valve
HM400-2 37
SEN00526-00 10 Structure, function and maintenance standard
38 HM400-2
10 Structure, function and maintenance standard SEN00526-00
1. Hoist control function reduce the shock when the dump body comes
When the engine is running, the EPC valve into contact with the chassis.
(electromagnetic proportional valve) and selec-
4. Control when starting switch is turned to ON,
tor valve are controlled according to the opera-
OFF, or START
tion of the dump control lever and operate the
Starting switch at ON:
dump body.
The output is set to HOLD, regardless of the
2. Lever positioner function position of the lever.
The dump control lever has four positions: If the engine is not started, even if the hoist
RAISE, HOLD, FLOAT, and LOWER. lever is operated, the condition remains at
If the dump control lever is operated to the HOLD.
RAISE position, the dump body is raised, and Starting switch at OFF:
when the top of the dump body reaches the set The hoist valve is closed and the dump body is
position of the body position sensor, the lever is held in position regardless of the position of the
returned to the HOLD position. lever.
Engine started:
3. Body seating speed control
Immediately after the engine is started, the out-
When the dump body is lowered and reaches
put is set to HOLD, regardless of the position of
the position just before it is seated, the area of
the lever. After the lever is moved to the HOLD
opening of the EPC valve is throttled to control
position, it becomes possible to carry out nor-
the lowering speed of the dump body and
mal operations.
HM400-2 39
SEN00526-00 10 Structure, function and maintenance standard
7. Calibration function
To absorb any inherent error in the dump body
potentiometer, calibration is carried out to rec-
ognize the dump body seating and the body cyl-
inder stopper condition.
40 HM400-2
10 Structure, function and maintenance standard SEN00526-00
1. Inter-axle differential lock control sion output shaft speed exceeds the set
The inter-axle differential lock is actuated auto- value.
matically, or manually by turning the inter-axle a The inter-axle differential lock is actuat-
differential lock switch ON/OFF. ed when electric current is output to the
electromagnetic proportional valve.
• Manual differential lock:
In the low speed ranges (F1, F2, F3, R1, 2. Left and right differential lock control (controlled
R2) or N, the inter-axle command is output by the retarder controller)
when the differential lock switch is ON. Depending on the setting of the left and right dif-
ferential lock selector switch, one of the follow-
• Emergency braking control (automatic): ing is selected:
The inter-axle differential lock command is (1) rear wheel left and right differential lock ON;
output when the travel speed is more than (2) front and rear wheel left and right differential
35 km/h and the brake is ON. lock ON; or
(3) front and rear wheel left and right differential
• Brake ON control (automatic): lock OFF.
The inter-axle differential lock command is If (1) or (2) is selected, the differential lock foot
output according to the difference in speed switch is pressed, and the speed range is low
between the front and rear axles when the (F1, F2, F3, R1, R2), the differential lock com-
brake is ON. mand is output.
HM400-2 41
SEN00526-00 10 Structure, function and maintenance standard
42 HM400-2
10 Structure, function and maintenance standard SEN00526-00
1. Lever
2. Rod
3. Spring
4. Spring
5. Retainer
6. Body
7. Body
8. Bushing
9. Solenoid
10. Nut
11. Rod
12. Detent spring
13. Retainer
14. Ball
15. Seat
16. Potentiometer
17. Lever
18. Rod
19. Rod
20. Detent spring
HM400-2 43
SEN00526-00 10 Structure, function and maintenance standard
Function
• When lever (1) is operated, rod (18) moves up or
down according to the amount the lever is oper-
ated, and rotates potentiometer (16).
• The amount the control lever is operated (trav-
els) is detected by the potentiometer, and this is
sent as a signal voltage to the controller.
• One potentiometer is installed and outputs two
related signal voltages as shown in the "Output
voltage characteristics" graph.
Operation
1. 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 actu-
ation of mechanical detent)
• When rods (2) and (11) are pushed in further,
ball (14) is being 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 protrusion
(b) of rod (19) by retainer (13) that is being 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 pro-
trusion (b) of rod (19), so the lever is held at the
FLOAT position.
44 HM400-2
10 Structure, function and maintenance standard SEN00526-00
2. Dump control lever FLOAT canceled 4. Dump control lever operated to RAISE
• When lever (1) is returned from the FLOAT posi- • When RAISE rod (18) is pushed by lever (1) and
tion, it is pushed down by a force greater than moves down, ball (14) contacts protrusion (a) of
the holding force of rod (19), detent spring (20), rod (19) during the stroke. (Before start of actu-
retainer (13), and ball (14). ation of mechanical detent)
• When rods (18) and (19) are pushed in further,
3. Dump control lever operated to LOWER ball (14) pushes up retainer (13) which is held by
• When lever (1) is operated further from the detent spring (20) and it escapes to the outside,
FLOAT position, it moves to the LOWER posi- and rod (19) passes over protrusion (a).
tion. • When this happens, rod (2) on the opposite side
• Rod (18) is pushed up by the spring (4) in accor- is pushed up by spring (4).
dance with the amount lever (1) is operated. • When an electric current is flowing to solenoid
• Lever (17) and rod (19), which are installed to (9), if rod (2) is pushed up, nut (10) is held in con-
the rotating shaft of potentiometer (16), are inter- tact with bushing (8).
connected, so a voltage matching the up or • As a result, rod (2) is held at the pushed up po-
down movement of the rod is output from poten- sition, so even if the lever is released, it is held
tiometer (16). at the RAISE position.
HM400-2 45
SEN00526-00 10 Structure, function and maintenance standard
46 HM400-2
SEN00526-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
48 HM400-2
SEN00527-00
HM400-2 1
SEN00527-00 10 Structure, function and maintenance standard
1. Pedal
2. Connector
Outline
Accelerator signal Idle validation signal
• This is installed under the operator’s cab. The • This is installed under the operator’s cab.
accelerator pedal and accelerator sensor are When the accelerator pedal is released, signal
connected by a link. When the accelerator pedal 2 (No. 5 pin) is connected to the ground; when
is depressed, the movement is passed through the accelerator pedal is depressed, signal 3
the link and rotates the shaft of the potentiome- (No. 6 pin) is connected to the ground.
ter inside the accelerator sensor. The engine controller then detects the condi-
As a result, the resistance changes. A fixed tion.
voltage is impressed between the No. 1 – 3 pins
of the potentiometer. A voltage signal corre-
sponding to the angle of the accelerator pedal is
sent from the No. 2 pin to the engine controller.
2 HM400-2
10 Structure, function and maintenance standard SEN00527-00
1. Thermistor
2. Plug
3. Wiring harness
4. Connector
Function
• The retarder oil temperature sensor is installed
on the retarder pipe. It converts a temperature
change into a change of thermistor resistance,
and transmits a signal to the T/M controller. The
T/M controller transmits the signal via the net-
work to the machine monitor panel, and the ma-
chine monitor panel displays a temperature
level. The temperature level displayed on the
monitor panel reaches a predetermined posi-
tion, the lamp flashes and the warning buzzer
sounds.
1. Sensor
2. Terminal
3. Connector
Function
• The steering oil temperature sensor is installed
to the steering and hoist piping. The sensor por-
tion detects the temperature, and when the oil
temperature goes above the specified level, the
warning lamps lights up and a message is dis-
played on the character display of the monitor
panel.
HM400-2 3
SEN00527-00 10 Structure, function and maintenance standard
1. Connector
2. Wire resistor
3. Arm
4. Float
Function
• The fuel sensor is installed to the side face of the
fuel tank. The float moves up and down accord-
ing to the fuel level. This movement of the float
is transmitted by the arm and actuates a variable
resistance. This sends a signal to the monitor
panel to indicate the remaining fuel level. When
the display of the monitor panel reaches a cer-
tain level, a warning lamp flashes.
4 HM400-2
10 Structure, function and maintenance standard SEN00527-00
Tilt sensor
Function
• The tilt sensor is installed to the rear of the chas-
sis. A magnet supported by a leaf spring is in-
stalled to a case charged with damper oil. It uses
the position in relation to the magnetic resis-
tance element to detect the tilt angle of the chas-
sis.
The magnet is supported by the leaf spring, so
it does not detect the front-to-rear tilt of the
chassis.
HM400-2 5
SEN00527-00 10 Structure, function and maintenance standard
1. Indicator
2. Spring
3. Adapter
Function
• The air cleaner clogging sensor is installed to
the outward port of the air cleaner. If the air
cleaner becomes clogged and reaches the set
pressure (negative pressure), the maintenance
warning lamp lights up to warn of the abnormal-
ity.
6 HM400-2
10 Structure, function and maintenance standard SEN00527-00
1. Connector
2. Float
3. Switch
Function
• The hydraulic oil level sensor is installed to the
side face of the hydraulic tank. When the oil
goes below the specified level, the float goes
down, the switch is turned OFF, and the mainte-
nance caution lamp lights up to warn of the ab-
normality.
HM400-2 7
SEN00527-00 10 Structure, function and maintenance standard
1. Bearing
2. Brush Ass'y
3. Connector
Function
• The body position sensor is installed to the rear
of the chassis. When the angle of the dump
body changes, the shaft rotates through the link
installed to the dump body, and the dump body
angle is detected.
8 HM400-2
10 Structure, function and maintenance standard SEN00527-00
HM400-2 9
SEN00527-00 10 Structure, function and maintenance standard
10 HM400-2
SEN00527-00 10 Structure, function and maintenance standard
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
12 HM400-2
SEN00915-01
HM400-2
HM400-2 1
SEN00915-01 20 Standard value table
Engine SAA6D140E-5
Exhaust temperature • Whole speed range (Ambient tempera- °C Max. 650 700
ture: 20 °C)
%
At sudden Max. 25 35
(Bosch
• Coolant temperature: acceleration (Max. 2.5) (3.5)
Exhaust gas color index)
Within operating range
Bosch
At high idle Max. 1.0 2.0
index
Intake valve mm 0.35 —
Valve clearance • At cold
Exhaust valve mm 0.57 —
Compression MPa Min. 4.1 2.8
Compression • Engine oil temperature: pressure {kg/cm²} {Min. 42} {29}
pressure 40 – 60 °C
Engine
2 HM400-2
20 Standard value table SEN00915-01
Operating effort
• Center of lever grip {kg} {2.2 ± 0.4} {Max. 2.0}
lever
relief pressure Within operating range MPa 2.64 ± 0.20 2.64 ± 0.20
High idle
• Shift lever: N {kg/cm²} {26.9 ± 2.0} {26.9 ± 2.0}
Oil pressure
HM400-2 3
SEN00915-01 20 Standard value table
clutch pressure • Torque converter oil temperature: {kg/cm²} {26.0 ± 1.5} {26.0 ± 1.5}
Transmission 3rd Within operating range MPa 2.45 ± 0.15 2.45 ± 0.15
clutch pressure • Engine: High idle {kg/cm²} {25.0 ± 1.5} {25.0 ± 1.5}
Transmission R clutch MPa 2.55 ± 0.15 2.55 ± 0.15
pressure {kg/cm²} {26.0 ± 1.5} {26.0 ± 1.5}
Inter-axle differential MPa 2.45 ± 0.15 2.45 ± 0.15
lock clutch pressure {kg/cm²} {25.0 ± 1.5} {25.0 ± 1.5}
Transmission lubricat-
MPa 0.20 ± 0.049 0.20 ± 0.049
ing oil pressure
{kg/cm²} {2.0 ± 0.5} {2.0 ± 0.5}
Power train
(For reference)
6.9 ± 10%
F1 km/h 6.9 ± 10%
(6.5)
11.1 ± 10%
F2 km/h 11.1 ± 10%
(10.0)
• Level ground
17.1 ± 5%
F3 • Coolant temperature: km/h 17.1 ± 5%
(15.2)
Within operating range
Traveling speed
Min. 20°C
MPa 2.45 ± 0.25 2.45 ± 0.25
Center differential • Engine: High idle {kg/cm²} {25 ± 2.5} {25 ± 2.5}
• Left and right differential lockup
switch: ON
MPa 2.45 ± 0.25 2.45 ± 0.25
Rear differential • Left and right differential lockup
pedal: Depressed {kg/cm²} {25 ± 2.5} {25 ± 2.5}
(66.5 ± 5) (66.5 ± 5)
N 5.9 – 9.8 3.0 – 14.7
Retarder
Operating effort
lever
4 HM400-2
20 Standard value table SEN00915-01
Retarder brake
• Torque converter stall speed rpm 1,090 1,090
braking performance
• Flat dry road
Foot brake braking
• 36.5 t loaded m Max. 22.3 Max. 22.3
distance
• Traveling speed: 32km/h
• Flat dry road
Parking brake
HM400-2 5
SEN00915-01 20 Standard value table
tion (dimensions a)
Suspension cylinder
(dimension a)
• On a level road surface MPpa 1.18 ± 0.15 1.18 ± 0.15
Pressure
• Dump body: Unloaded {kg/cm²} {12.0 ± 1.5} {12.0 ± 1.5}
Hold o N Max. 29.4 Max. 35.3
Raise {kg} {Max. 3.0} {Max. 3.6}
Raise o N
Must return smoothly
Hold {kg}
Hold o N Max. 29.4 Max. 35.3
• Engine stopped Float {kg} {Max. 3.0} {Max. 3.6}
Dump lever operating effort
• Center of grip Float o N Max. 29.4 Max. 35.3
Hold {kg} {Max. 3.0} {Max. 3.6}
Float o N Max. 29.4 Max. 35.3
Lower {kg} {Max. 3.0} {Max. 3.6}
Lower o N
Must return smoothly
Float {kg}
6 HM400-2
20 Standard value table SEN00915-01
HM400-2 7
SEN00915-01 20 Standard value table
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
8 HM400-2
SEN00916-01
HM400-2 1
SEN00916-01 30 Testing and adjusting
2 HM400-2
30 Testing and adjusting SEN00916-01
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Testing air boost pressure -101 – 200 kPa
A 799-201-2202 Boost gauge kit 1
(boost pressure) {-760 – 1,500 mmHg}
Testing exhaust tempera- Digital temperature
B 799-101-1502 1 -99. 9 – 1,299 °C
ture gauge
1 799-201-9001 Handy smoke checker 1
Testing exhaust gas color C Commercial Bosch index: 0 – 9
2 Smoke meter 1
item
Commercial
Adjusting valve clearance D Clearance gauge 1 Intake: 0.35 mm, Exhaust: 0.57 mm
item
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm²}
Testing compression
E 795-471-1330 Adapter 1
pressure 2 For 140E-5 engine
6261-71-6150 Gasket 1
Testing blow-by pressure F 799-201-1504 Blow-by checker 1 0 - 5kPa {0 - 500mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm²}
Testing engine oil pressure G Digital type hydraulic Pressure gage:
790-261-1204 1
tester 58.8 MPa {600 kg/cm²}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
0.98MPa {10kg/cm²}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39. 2,58. 8MPa
1 {25, 60, 400, 600kg/cm²}
Pressure gage:
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure H 58. 8MPa {600kg/cm²}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
0. 98MPa {10kg/cm²}
795-471-1450 Adapter 1
3 8 × 1.25mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inner diameter: 14mm
2 6206-71-1770 Joint 1 Inner diameter of joint part: 10mm
Commercially
3 Hose 1 ø5 mm × 2 – 3 m
available
Testing fuel return and leak- Commercially
J 4 Hose 1 ø15 mm × 2 – 3 m
age amount available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm²}
Testing power train oil
K Pressure gage:
pressure 790-261-1204 Digital hydraulic tester 1
58. 8MPa {600kg/cm²}
Pressure gauge:
2 799-401-2320 Hydraulic tester 1
0.98MPa {10kg/cm²}
HM400-2 3
SEN00916-01 30 Testing and adjusting
Sym-
Q'ty
Testing and adjusting item Part No. Part name Remarks
bol
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39. 2, 58. 8 MPa
Testing and adjusting differ- {25, 60, 400, 600 kg/cm²}
L
ential lockup oil pressure
Pressure gage:
790-261-1204 Digital hydraulic tester 1
58. 8MPa{600 kg/cm²}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39. 2, 58. 8 MPa
Testing and adjusting brake 1 {25, 60, 400, 600 kg/cm²}
M
oil pressure Pressure gauge:
790-261-1204 Digital hydraulic tester 1
58. 8 MPa {600 kg/cm²}
2 793-520-1805 Brake test kit 1 19. 6 Mpa {200 kg/cm²}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39. 2, 58. 8 MPa
Testing and adjusting steer- {25, 60, 400, 600 kg/cm²}
N
ing circuit oil pressure
Pressure gage:
790-261-1204 Digital hydraulic tester 1
58. 8 MPa {600 kg/cm²}
1 792-610-1000 Suspension tool 1
2 792-610-1130 • Pump 1
3 792-610-1110 • Hose 1
4 792-610-1120 • Joint 1
P2 – P6: Pump assembly
5 07020-21731 • Fitting 1
(Kit part No: 792-610-1100)
6 792-610-1140 • Joint 1
Testing and adjusting sus- P7 – P13: Charging tool assembly
P 7 792-610-1250 • Valve 1
pension cylinder (Kit part No: 792-610-1200)
8 792-610-1260 • Nipple 1
9 792-610-1480 • Stem 1
10 792-610-1640 • Joint 1
11 792-610-1400 • Regulator 1
12 792-610-1430 • Gauge 1 24. 5 MPa {250 kg/cm²}
13 792-610-1440 • Gauge 1 9.8 MPa {100 kg/cm²}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58. 8 MPa
Testing and adjusting dump {25, 60, 400, 600 kg/cm²}
Q
circuit oil pressure
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
58. 8MPa {600kg/cm²}
Testing water temperature Digital temperature
– 799-101-1502 1 -99. 9 – 1,299 °C
and oil temperature gauge
Testing operation effort and – 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
pedal effort – 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Testing stroke and hydrau- Commercially
– Scale 1
lic drift available
Testing work equipment Commercially
– Stopwatch 1
speed available
Testing voltage and resis- Commercially
– Tester 1
tance available
a For the types and part numbers of T-adapter box and T-adapter which are used for troubleshooting of
machine monitor, controller, sensor, actuator, electrical equipment and harnesses, see "T-adapter box
and T-adapter table in troubleshooting (general information on troubleshooting).
4 HM400-2
30 Testing and adjusting SEN00916-01
HM400-2 5
SEN00916-01 30 Testing and adjusting
Testing intake air pressure (boost a If any oil is left in the hose, the gauge does
not move. Accordingly, be sure to drain
pressure) 1 the oil.
a Testing instruments of intake air pressure
(boost pressure) 5. Turn the parking brake switch ON, depress the
brake pedal, and then set the gear shift lever to
Symbol Part number Part name
the D position.
A 799-201-2202 Boost gauge kit k If the gearshift lever is operated to any
position other than the D position, the
k Stop the machine on the level ground, turn machine may move off even if the brake is
the parking brake switch ON, and set being depressed, so always test at the D
chocks to the tires. position.
k When installing and removing the testing
instrument, take care not to touch a hot part 6. Depress the accelerator pedal gradually and
of the engine. check intake air pressure while the engine is
running at high idle and the torque converter is
1. Open the engine hood. stalling.
k There is danger of damage to the internal
2. Remove intake air pressure inspection plug (1) parts of the transmission, so never operate
from aftercooler piping. the gear shift lever to any position other
than the D position during the stall opera-
tion.
a After completing the test, lower the engine
speed to low idle, then return the gearshift
lever to the N position.
6 HM400-2
30 Testing and adjusting SEN00916-01
Testing exhaust temperature 1 2) Turn the parking brake switch ON, de-
press the brake pedal, and then set the
a Testing instrument for exhaust temperature gear shift lever to the D position.
Symbol Part number Part name k If the gearshift lever is operated to
B 799-101-1502 Digital temperature gauge any position other than the D posi-
tion, the machine may move off
k Stop the machine on the level ground, turn even if the brake is being
the parking brake switch ON, and set depressed, so always check at the
chocks to the tires. D position.
k Install and remove the testing instrument 3) Depress the accelerator pedal gradually,
after the exhaust manifold is cooled. run the engine at high idle and stall the
torque converter. At the same time, oper-
1. Open the engine hood and remove the turbo- ate the dump lever to the LOWER position
charger heat insulation cover. and relieve the oil pressure (full stall).
2. Remove exhaust temperature testing plug (1), a Continue until the exhaust temperature
which is in the middle of exhaust manifold. reaches the standard value of 650 °C.
k There is danger of damage to the inter-
nal parts of the transmission, so never
operate the gear shift lever to any posi-
tion other than the D position during
the stall operation.
4) When the temperature stabilizes at near
the target temperature, return the dump
lever to NEUTRAL and check the tempera-
ture with only the torque converter stalled.
a The exhaust temperature will start to
go down from the full stall condition,
so measure the temperature when it
stabilizes.
a If the exhaust temperature does not
3. Install sensor [1] of digital temperature gauge
go down but rises, make the set tem-
(B) and connect it to meter [2].
perature at full stall higher.
a Clamp the wiring harness of the digital
a After completing the test, lower the
thermometer so that it does not touch a
engine speed to low idle, then return
hot part during measurement.
the gearshift lever to the N position.
HM400-2 7
SEN00916-01 30 Testing and adjusting
8 HM400-2
30 Testing and adjusting SEN00916-01
Adjusting valve clearance 1 4. Loosen locknut (4) with adjustment screw (3)
fixed
a Adjusting instrument for valve clearance a After setting the No. 1 cylinder at the com-
Symbol Part number Part name pression top dead center, adjust valve
clearance of No. 1 cylinder.
Commercially
D Clearance gauge
available
5. To adjust the valve clearance, insert clearance
k
gauge D into clearance between rocker arm
Stop the machine on the level ground, turn
(5) and crosshead (6), and adjust the valve
the parking brake switch ON, and set
clearance with adjustment screw (3).
chocks to the tires.
a With the clearance gauge inserted, turn
the adjustment screw so that clearance
1. Open the engine hood. gauge can move with a light force.
a Valve clearance
2. Remove all cylinder head covers (1). Intake valve: 0.35 mm,
Exhaust valve: 0.57 mm
HM400-2 9
SEN00916-01 30 Testing and adjusting
10 HM400-2
30 Testing and adjusting SEN00916-01
HM400-2 11
SEN00916-01 30 Testing and adjusting
12 HM400-2
30 Testing and adjusting SEN00916-01
Testing engine oil pressure 1 5. Test engine oil pressure at low idle and torque
converter stall.
a Testing instruments for engine oil pressure a For the operation method of torque con-
Symbol Part number Part name verter stall, see Testing and adjusting
"Testing blow-by pressure".
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
HM400-2 13
SEN00916-01 30 Testing and adjusting
14 HM400-2
30 Testing and adjusting SEN00916-01
Testing fuel pressure 1 4. Run the engine at high idle and test fuel pres-
sure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
Symbol Part number Part name range, it is normal.
799-101-5002 Hydraulic tester
1 Engine speed Fuel pressure
790-261-1204 Digital hydraulic tester
0.15 – 0.3 Mpa
H 2 799-401-2320 Hydraulic tester High idle
{1.5 – 3 kg/cm²}
795-471-1450 Adapter
3
07005-00812 Gasket
HM400-2 15
SEN00916-01 30 Testing and adjusting
16 HM400-2
30 Testing and adjusting SEN00916-01
HM400-2 17
SEN00916-01 30 Testing and adjusting
3. Testing injector return amount return amount per minute with measuring
a During testing injector return amount, cylinder J5.
keep a hose end connected to pressure a Refer to "Testing torque converter
limiter and insert the other end to oil pan stall" for torque converter stall proce-
(receiver). dure.
1) Disconnect return hose (5) of return block a The leakage also can be judged by
(4) portion and connect inspection hose testing for twenty seconds and triples
J4. its leakage amount.
a Block the return hose side with plug a If there is loss of pressure feed from
and fix to fuel tank side. supply pump, the engine speed may
Plug: 07376-70315 not rise. In this case, record the
a Bind connecting portion with wire so engine speed during the test.
that the inspection hose should not a If the return amount of injector (spill
come off. amount) is in the following range, it is
2) Adjust the route of inspection hose J4 to normal.
remove its sag and insert the hose end Torque converter Return limit amount
into the oil pan (receiver). stall speed (spill)
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
18 HM400-2
30 Testing and adjusting SEN00916-01
HM400-2 19
SEN00916-01 30 Testing and adjusting
20 HM400-2
30 Testing and adjusting SEN00916-01
Testing the fuel circuit for leak- 9. Check the fuel piping and the devices for fuel
leakage.
age 1 a Check the high-pressure circuit parts con-
k Very high pressure is generated in the high- centrating on the areas coated with the
pressure circuit of the fuel system. If fuel color checker, for fuel leakage.
leaks while the engine is running, it is dan- a If any fuel leakage is detected, repair it
gerous since it can catch fire. and test again from step 1.
a After testing the fuel system or removing and a If any fuel leakage is not detected, inspec-
installing its components, check for fuel leak- tion is completed.
age according to the following procedure.
a Clean and degrease the engine and the parts
around it in advance so that you can check it
easily for fuel leakage.
HM400-2 21
SEN00916-01 30 Testing and adjusting
Testing
1. Open the engine hood.
Adjusting
a If the deflection is out of range, adjust it ac-
cording to the following procedure.
22 HM400-2
30 Testing and adjusting SEN00916-01
Testing and adjusting alternator 4. While holding adjustment nut (6), tighten lock-
nut (5).
belt tension 1
k Stop the machine on the level ground, turn 5. Loosen mounting bolts (4) (3) of alternator (2).
the parking brake switch ON, and set a After adjusting, check the belt tension
chocks to the tires. again.
Adjusting
a If the deflection is out of range, adjust it ac-
cording to the following procedure.
HM400-2 23
SEN00916-01 30 Testing and adjusting
Testing
1. Open the engine hood.
Adjusting
a If the deflection is out of range, adjust it ac-
cording to the following procedure.
24 HM400-2
30 Testing and adjusting SEN00916-01
HM400-2 25
SEN00916-01 30 Testing and adjusting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
26 HM400-2
SEN00917-01
HM400-2 1
SEN00917-01 30 Testing and adjusting
2 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 3
SEN00917-01 30 Testing and adjusting
4 HM400-2
30 Testing and adjusting SEN00917-01
a Testing instruments for power train oil pressure Overall power train
1. Testing power train main relief pressure
Symbol Part number Part name
1) Tilt the cab up.
799-101-5002 Hydraulic tester 2) Remove oil pressure inspecting plug (1),
1
K 790-261-1204 Digital type hydraulic tester then install nipple [1] and hose [2] of
2 799-401-2320 Hydraulic tester hydraulic tester K1.
a Pull the hose out to the rear of the
k Stop the machine on the level ground, turn transmission.
the parking brake switch ON, and set
chocks to the tires.
k Install and remove the testing instrument
after the oil temperature is cooled enough.
k When testing the oil pressure while travel-
ing, make sure that there is a wide travel
area and pay attention to keep the safety in
the surrounding area.
a When tilting the cab up or down, see "Method
of tilting cab up" for details.
HM400-2 5
SEN00917-01 30 Testing and adjusting
6 HM400-2
30 Testing and adjusting SEN00917-01
speed
Travel
hydraulic tester K1. R2 R1 N D 5 4 3 2 1 Lo Hi 1st 2nd 3rd R
Q Q Q Q Q F1 q q
Q Q Q Q Q F2 q w
Q Q Q Q F3 w q
Q Q Q F4 w w
Q Q F5 w q
Q F6 w w
Q N
Q R1 w q
Q R2 w w
HM400-2 7
SEN00917-01 30 Testing and adjusting
5. Testing transmission Lo clutch pressure 2) Remove oil pressure inspecting plug (6),
1) Remove ECMV cover. then install nipple [1] and hose [2] of
2) Remove oil pressure inspecting plug (5), hydraulic tester K1.
then install nipple [1] and hose [2] of
hydraulic tester K1.
8 HM400-2
30 Testing and adjusting SEN00917-01
7. Testing transmission 1st clutch pressure 8. Testing transmission 2nd clutch pressure
1) Remove ECMV cover. 1) Remove ECMV cover.
2) Remove oil pressure inspecting plug (7), 2) Remove oil pressure inspecting plug (8),
then install nipple [1] and hose [2] of then install nipple [1] and hose [2] of
hydraulic tester K1. hydraulic tester K1.
3) Connect oil pressure gauge [3] of hydrau- 3) Connect oil pressure gauge [3] of hydrau-
lic tester K1. lic tester K1.
a If oil pressure gauges are of the ana- a If oil pressure gauges are of the ana-
log type, use the one with rated pres- log type, use the one with rated pres-
sure 5.9 MPa {60 kg/cm²}. sure 5.9 MPa {60 kg/cm²}.
4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF, depress 5) Turn the parking brake switch OFF, depress
the brake pedal, then set the gear shift lever the brake pedal, then set the gear shift lever
to position 1. to position 3.
6) Release the brake and inspect the oil 6) Release the brake, travel at high idle, and
pressure when traveling at high idle. inspect the oil pressure when the shift
k
indicator displays [F3].
In F1 gear speed, the maximum
travel speed reaches approx. 7 km/ k In F3 gear speed, the maximum
h, so drive the machine consider- travel speed reaches approx. 17
ing the safety of the surrounding km/h, so drive the machine consid-
area. ering the safety of the surrounding
area.
HM400-2 9
SEN00917-01 30 Testing and adjusting
9. Testing transmission 3rd clutch pressure 10. Testing transmission R clutch pressure
1) Remove ECMV cover. 1) Remove ECMV cover.
2) Remove oil pressure inspecting plug (9), 2) Remove oil pressure inspecting plug (10),
then install nipple [1] and hose [2] of then install nipple [1] and hose [2] of
hydraulic tester K1. hydraulic tester K1.
3) Connect oil pressure gauge [3] of hydrau- 3) Connect oil pressure gauge [3] of hydrau-
lic tester K1. lic tester K1.
a If oil pressure gauges are of the ana- a If oil pressure gauges are of the ana-
log type, use the one with rated pres- log type, use the one with rated pres-
sure 5.9 MPa {60 kg/cm²}. sure 5.9 MPa {60 kg/cm²}.
4) Start the engine and raise the temperature 4) Start the engine and raise the temperature
of the torque converter oil to the operating of the torque converter oil to the operating
range. range.
5) Turn the parking brake switch OFF, depress 5) Turn the parking brake switch OFF, depress
the brake pedal, then set the gear shift lever the brake pedal, then set the gear shift lever
to position 5. to position R1.
6) Release the brake, travel at high idle, and 6) Release the brake and inspect the oil
inspect the oil pressure when the shift pressure when traveling at high idle.
k
indicator displays [F5].
In R1 gear speed, the maximum
k In F5 gear speed, the maximum travel speed reaches approx. 7 km/
travel speed reaches approx. 40 h, so drive the machine consider-
km/h, so drive the machine consid- ing the safety of the surrounding
ering the safety of the surrounding area.
area.
10 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 11
SEN00917-01 30 Testing and adjusting
12 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 13
SEN00917-01 30 Testing and adjusting
14 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 15
SEN00917-01 30 Testing and adjusting
16 HM400-2
30 Testing and adjusting SEN00917-01
a There are 4 speed sensors installed to the 4) Tighten nut (3) with sensor (1) fixed.
transmission. Adjust each sensor according to 3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
the following procedure.
N1 : Input shaft speed sensor
N2 : Intermediate shaft speed sensor
N3 : Output shaft R speed sensor
FE1 : Output shaft F speed sensor
a For the input shaft speed sensor, tilt up the cab
before carrying out adjustment.
a For the intermediate shaft speed sensor, out-
put shaft F speed sensor and output shaft R
speed sensor, remove the transmission and
front differential assembly from machine before
carrying out adjustment.
HM400-2 17
SEN00917-01 30 Testing and adjusting
a Clearance (b) which is created be- 2) Screw in sensor (10) until its tip touches
tween the sensor tip and addendum the addendum of front output shaft gear
is 0.75 – 1.5 mm. (11).
4) Tighten nut (6) with sensor (4) fixed. 3) Return sensor (10) by 1/2 – 1 turn from
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm} that position.
a Clearance (d) which is created be-
tween the sensor tip and addendum
is 0.75 – 1.5 mm.
4) Tighten nut (12) with sensor (10) fixed.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
18 HM400-2
30 Testing and adjusting SEN00917-01
Testing and adjusting brake oil 2] Inspect the pressure at the point
where the indicator of oil pressure
pressure 1 gauge [2] stops going down and
a Equipment for testing and adjusting brake oil starts to go up again.
pressure 4) Inspect the cut-out pressure at high idle.
Check the oil pressure when the pressure
Symbol Part number Part name
goes up after the cut-in and the indicator
799-101-5002 Hydraulic tester of oil pressure gauge [2] stops.
1
M 790-261-1204 Digital hydraulic tester
2 793-520-1805 Brake test kit
Testing
1. Testing the charge valve cut-in pressure
and cut-out pressure
a Inspect the charge valve oil pressure at
remote pressure pickup port (1).
HM400-2 19
SEN00917-01 30 Testing and adjusting
2. Testing the wheel brake actuating pressure 5) Inspect the drop in pressure of the foot
and drop in pressure brake under the following conditions.
a Inspect the front brake circuit, center a Check that the actuating pressure of
brake circuit and rear brake circuit using both the foot brake and the retarder
the same procedure. are normal before starting to mea-
1) Remove air bleeder (2) of the slack sure.
adjuster. 1] Run the engine for several minutes at
low idle to charge the accumulator,
then stop the engine.
2] Depress the brake pedal fully and
inspect the oil pressure.
a Keep the brake pedal depressed.
3] Inspect the oil pressure after 5 min-
utes and calculate the drop in pres-
sure.
6) When the test is completed, remove the
instruments and restore to the original
condition.
a Bleed the air from the brake circuit
referring to "Bleeding air from brake
circuit" section.
2) Install brake test kit M2 and bleed the air
from the brake circuit.
a For details, see "Bleeding air from
brake circuit" section.
20 HM400-2
30 Testing and adjusting SEN00917-01
3. Inspect the actuating pressure of the park- 6) When the test is completed, remove the
ing brake instruments and restore to the original
1) Turn the parking brake switch ON. condition.
k
2) Remove oil pressure inspection plug (3) in
Check that the parking brake
parking brake cylinder piping.
switch is ON before carrying out
the operation.
HM400-2 21
SEN00917-01 30 Testing and adjusting
Adjusting
Adjusting charge valve cut-in pressure and cut-
out pressure
a If the charge valve cut-in pressure or cut-out
pressure is not normal, adjust the R1 relief
valve of charge valve (4) according to the fol-
lowing procedures.
a Both cut-in pressure and cut-out pressure
change by adjusting the R1 relief valve.
22 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 23
SEN00917-01 30 Testing and adjusting
Bleeding air from brake circuit 1 5) After completing air bleeding, set to the
original condition.
a Bleed the air from brake circuit as follows if the
brake circuit equipment has been removed and 2. Bleeding air from wheel brake section of
installed. foot brake circuit.
a When bleeding the air from the wheel brake a Implement the same procedure for the
circuit, always bleed the air from the slack front brake circuit, center brake circuit and
adjuster section first, then bleed the air from rear brake circuit.
the wheel brake section. a The retarder oil pressure caution lamp
may light up while air is being bled. If it
1. Bleeding air from slack adjuster section of lights up, tighten the air bleeder and check
wheel brake circuit the oil level in the brake oil tank by the
a Implement the same procedure for the sight gauge. If the oil level is low, add oil.
front brake circuit, center brake circuit and 1) Connect air bleed hose [2] to air bleeder
rear brake circuit. (2).
a The retarder oil pressure caution lamp
may light up while air is being bled. If it
lights up, tighten the air bleeder and check
the oil level in the brake oil tank by the
sight gauge. If the oil level is low, add oil.
1) Connect air bleed hose [1] to air bleeder
(1).
24 HM400-2
30 Testing and adjusting SEN00917-01
Testing wear of wheel brake disc 1 a Limit mark (b) indicates the wear limit for
the disc.
k Stop the machine on the level ground, turn If limit mark (b) reaches the end face of
the parking brake switch ON, and set guide (3), the disc has reached the wear
chocks to the tires. limit.
k Carry out the test when the brake oil tem-
perature is less than 60 °C.
k When the disc comes close to the wear
limit, carry out the test more frequently. Be
sure to test a braking performance of
retarder brake at the same time.
HM400-2 25
SEN00917-01 30 Testing and adjusting
26 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 27
SEN00917-01 30 Testing and adjusting
28 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 29
SEN00917-01 30 Testing and adjusting
30 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 31
SEN00917-01 30 Testing and adjusting
32 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 33
SEN00917-01 30 Testing and adjusting
2. Tilting cab up
Method using built-in cylinder
1) Move pin (1) at the cab rear mount from
hole (2) to hole (4).
34 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 35
SEN00917-01 30 Testing and adjusting
Testing and adjusting dump 3) Operate the dump lever with the engine
running at high idle and measure the oil
circuit oil pressure 1 pressure at RAISE relief or LOWER relief.
a Equipments for testing and adjusting dump cir-
cuit oil pressure
Symbol Part number Part name
799-101-5002 Hydraulic tester
Q
790-261-1204 Digital hydraulic tester
36 HM400-2
30 Testing and adjusting SEN00917-01
3. Testing dump pilot relief oil pressure 5) When the test is completed, remove the
1) Remove the side cover of hydraulic oil instruments and restore to the original
tank. condition.
2) Remove oil pressure inspection plug (5).
4. Adjusting dump pilot relief oil pressure
a If the dump pilot relief oil pressure is not
normal, adjust it with relief valve (6)
according to the following procedures.
HM400-2 37
SEN00917-01 30 Testing and adjusting
38 HM400-2
30 Testing and adjusting SEN00917-01
HM400-2 39
SEN00917-01 30 Testing and adjusting
1. When any problem occurs in the engine control system and the engine cannot be started:
a Decide the escape method according to the following flowchart.
a Refer to "Special functions of machine monitor" for the method of checking the failure code.
Note: If the engine cannot be started and the machine is to be towed, release the parking brake temporarily
referring to "Method for emergency release of parking brake", since it cannot be released by operating
the switch.
40 HM400-2
30 Testing and adjusting SEN00917-01
2. When any problem occurs in the transmission control system and the machine cannot be
started:
a Check the failure code, and determine an adequate escape procedure from following table.
a Refer to "Special functions of machine monitor" for the method of checking the failure code.
Failure Condition when Lever position for speed range to
Escape method Remarks
code failure occurs move off after escape operation
1500L0 Occurrence condition 2 Escape procedure 2 — Occurrence condition 1:
Gear speed remains fixed and will
15G0MW Occurrence condition 7 Escape procedure 1 D – 1: F2 speed
not shift from that position when
15H0MW Occurrence condition 7 Escape procedure 1 D – 1: F1 speed, R1 – R2: R1 speed restarting.When gear shift lever is
15J0MW Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed shifted to N, transmission is set to
neutral.
15K0MW Occurrence condition 7 Escape procedure 3 D – 1: F3 speed, R1 – R2: R2 speed
15L0MW Occurrence condition 7 Escape procedure 3 D – 1: F2 speed, R1 – R2: R1 speed Occurrence condition 2:
Transmission suddenly shifts to
15M0MW Occurrence condition 7 Escape procedure 3 D – 1: F2 speed, R1 – R2: R1 speed
neutral while traveling. And after
15SBL1 Occurrence condition 7 Escape procedure 1 R1 – R2: R1 speed machine is stopped, operating lever
15SBMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed does not shift the transmission from
neutral and machine can not move
15SCL1 Occurrence condition 7 Escape procedure 1 D – 1: F2 speed off.
15SCMA Occurrence condition 7 Escape procedure 1 D – 1: F1 speed, R1 – R2: R1 speed
Occurrence condition 3:
15SDL1 Occurrence condition 7 Escape procedure 1 D – 1: F1 speed
Transmission suddenly shifted to
15SDMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed neutral while traveling.
15SEL1 Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
Occurrence condition 4:
15SEMA Occurrence condition 7 Escape procedure 1 D – 1: F3 speed, R1 – R2: R2 speed
Even if the lever is operated after
15SFL1 Occurrence condition 7 Escape procedure 1 D – 1: F3 speed, R1 – R2: R2 speed the engine is started, the transmis-
sion stays in neutral and the
15SFMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
machine cannot be started.
D – 1: F5 speed,
15SGL1 Occurrence condition 7 Escape procedure 1
R1 – R2: R3 or equivalent speed Occurrence condition 5:
15SGMA Occurrence condition 7 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed Response of lever became abnor-
mal and lever operation did not
15SJMA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed work. When lever was forced to
Normal traveling is possible if display operate, transmission shifted to
DAQ0KK Occurrence condition 1 Escape procedure 5
returns to normal (Note 1) neutral.
Normal traveling is possible if display
DAQ2KK Occurrence condition 1 Escape procedure 4 Occurrence condition 6:
returns to normal (Note 1)
Speed range remains fixed, and
DAQ9KQ Occurrence condition 4 Escape procedure 6 — when machine moves off again, the
Normal traveling is possible if display transmission does not shift from the
DAQRKR Occurrence condition 2 Escape procedure 5 fixed speed range. If lever is posi-
returns to normal (Note 1)
tioned at N, transmission shifts to
DAQRMA Occurrence condition 4 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed neutral, and after that, it can not be
DB2RKR Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed shifted.
DDTHKA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed
Occurrence condition 7:
DDTJKA Occurrence condition 1 Escape procedure 1 D – 1: F1 speed Gear speed is fixed with appropri-
DDTKKA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed ate clutches applied for the travel. If
appropriate clutches are not avail-
DDTLKA Occurrence condition 1 Escape procedure 1 D – 1: F3 speed, R1 – R2: R2 speed
able for the travel, transmission
D – 1: F5 speed, shifts to neutral. If lever is posi-
DDTMKA Occurrence condition 1 Escape procedure 1
R1 – R2: R3 or equivalent speed tioned at N, transmission shifts to
neutral.
DDTNKA Occurrence condition 1 Escape procedure 1 R1 – R2: R1 speed
Normal traveling is possible if display Note 1:
DF10KA Occurrence condition 5 Escape procedure 7
returns to normal (Note 1) Even when the machine condition is
Normal traveling is possible if display restored after a failure, the neutral
DF10KB Occurrence condition 5 Escape procedure 7 condition is maintained until the
returns to normal (Note 1)
lever is returned to the N position.
DLF1KA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
DLF1LC Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
DLF2KA Occurrence condition 1 Escape procedure 1 D – 1: F2 speed, R1 – R2: R1 speed
HM400-2 41
SEN00917-01 30 Testing and adjusting
Escape procedure 1:
1) Stop traveling and return the shift lever to N position.
2) Operate the gear shift lever again and move the machine off.
a When operating the gearshift lever, release the accelerator pedal.
a Shift lever operation: N o D – 1, or N o R1 – R2
Escape procedure 2:
Tow the machine.
a If the engine cannot be started and the machine is to be towed, release the parking brake temporarily
referring to "Method for emergency release of parking brake", since it cannot be released by operating
the switch.
Escape procedure 3:
1) Stop traveling and return the shift lever to N position.
2) Connect and disconnect the emergency escape connectors A1 (female) and A2 (male) temporarily, and
switch to the emergency escape mode.
a Connectors A1 and A2 are installed in front of the transmission controller.
a Connect and disconnect the connectors with the starting switch ON or with the engine started.
3) Operate the gear shift lever and move the machine off again.
a When operating the gearshift lever, release the accelerator pedal.
a Shift lever operation: N o D – 1, or N o R1 – R2
a The emergency escape mode is maintained until the starting switch is turned OFF.
42 HM400-2
30 Testing and adjusting SEN00917-01
Escape procedure 4:
Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
q Circuit breaker: No.64 (80A), No.65 (80A)
q Fuse: BT3-No.14 (10A)
Escape procedure 5:
Check the circuit breaker and fuse, and if they are normal, replace the transmission controller.
q Circuit breaker: Inside battery housing (30A)
q Fuse: BT2-No.22 (10A)
Escape procedure 6:
Reset the model selection setting, then reset the selection of options.
a To check the model and option selection setting, refer to the section "Setting and adjusting of each
equipment".
Escape procedure 7:
Check the fuse, and if it is normal, replace the gear shift lever.
q Fuse: BT3-No.14 (10A)
HM400-2 43
SEN00917-01 30 Testing and adjusting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
44 HM400-2
SEN00918-01
HM400-2 1
SEN00918-01 30 Testing and adjusting
2 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 3
SEN00918-01 30 Testing and adjusting
a Even if the model presently set is cor- 2) After selecting the model in the model
rect, be sure to carry out the setting selecting screen, determine the model by
newly. pressing the [U] switch.
q [U]: Determine the setting.
q [ t]: To cancel the setting
a The below figure shows the example
that HM400-2 has been selected.
4 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 5
SEN00918-01 30 Testing and adjusting
6 HM400-2
30 Testing and adjusting SEN00918-01
2) After confirming the installation condition 2) After confirming the installation condition
of the left-and-right differential lock-up and of the body up caution and the setting sta-
the setting status on the screen, press the tus on the screen, press the [U] switch
[U] switch and determine the setting. and determine the setting.
q [U]: To change setting. q [U]: To change setting.
(Display is changed.) (Display is changed.)
q [t]: To return to optional item selec- q [t]: To return to optional item selec-
tion screen. tion screen.
q ADD: To set option. q ADD: To set option.
q NO ADD: Not to set option. q NO ADD: Not to set option.
a If the setting is once determined by a If the setting is once determined by
pressing the [U] switch, it is effective pressing the [U] switch, it is effective
even after the screen is terminated. even after the screen is terminated.
HM400-2 7
SEN00918-01 30 Testing and adjusting
6. Setting of dozing counter (06: DUMP COUNT) 7. Setting of tire size compensation (08: TIRE
1) Select the dozing counter (06: DUMP SIZE)
COUNT) in the option item selecting 1) Select the tire size compensation (08:
screen. TIRE SIZE) in the option item selection
a The present setting status is dis- screen.
played at the left of the lower row. a The present compensation value is
(ADD: Option is set. NO ADD: Option displayed at the left of the lower row.
is not set.) (***%: Rate of change from standard
tire)
8 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 9
SEN00918-01 30 Testing and adjusting
10. Setting of economy mode (12: E1 MODE) 1-3. OFF setting of maintenance monitor (corro-
1) Select the economy mode (12: E1 MODE) sion resistor)
in the optional item selection screen. 1. Switching to service mode
a The present setting status is dis- Switch to the service mode by referring to "1-1.
played at the left of the lower row. Setting of model selection".
(ADD: Option is set. NO ADD: Option
is not set.) 2. Selecting and carrying out service menu
1) Select the filter and oil replacement time
setting function (MAINTENANCE MONI-
TO R) in the service menu selection
screen referring to "1-1. Setting of model
selection".
10 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 11
SEN00918-01 30 Testing and adjusting
12 HM400-2
30 Testing and adjusting SEN00918-01
Operator mode
HM400-2 13
SEN00918-01 30 Testing and adjusting
Service mode
a No. 9 – No. 19 is displayed endlessly by follow-
ing the switch operation.
a By inputting and determining the ID once, it will
be effective until the starting switch is turned
off.
14 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 15
SEN00918-01 30 Testing and adjusting
16 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 17
SEN00918-01 30 Testing and adjusting
18 HM400-2
30 Testing and adjusting SEN00918-01
2A62L1 Front wheels differential lockup control valve system failure BK E01 Electrical system
2A62LH Front wheels differential lockup control valve system failure BK E01 Electrical system
2B62L1 Rear wheels differential lockup control valve system failure BK E01 Electrical system
2B62LH Rear wheels differential lockup control valve system failure BK E01 Electrical system
2C4MNX Retarder cooling filter clogging MON E01 Mechanical system
2F00KM Dragging of parking brake TM – Mechanical system
2G42ZG Decrease of accumulator oil pressure (Front) BK E03 Mechanical system
2G43ZG Decrease of accumulator oil pressure (Rear) BK E03 Mechanical system
(989A00) Engine over run prevention activated MON E02 –
A570NX Engine oil filter clogging TM E01 Mechanical system
AA10NX Clogged air cleaner MON E01 Mechanical system
AB00MA Failure of battery charge circuit TM E03 Electrical system
B@BAZG Engine oil pressure is too low. ENG E03 Mechanical system
B@BAZK Engine oil level is too low. TM E01 Mechanical system
B@BCNS Engine overheat ENG E02 Mechanical system
B@BCZK Coolant level is too low. MON E01 Mechanical system
B@C6NS Overheat of brake cooling oil temperature (Front) MON E02 Mechanical system
HM400-2 19
SEN00918-01 30 Testing and adjusting
20 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 21
SEN00918-01 30 Testing and adjusting
22 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 23
SEN00918-01 30 Testing and adjusting
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
BK : Retarder controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
24 HM400-2
30 Testing and adjusting SEN00918-01
t Service mode
Procedure for switching to service mode and
screen display
a When using the service mode, change the
screen by the following special operation.
HM400-2 25
SEN00918-01 30 Testing and adjusting
26 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 27
SEN00918-01 30 Testing and adjusting
[10] Mechanical system failure history display 4: Elapsed time 2 (time elapsed on service
function (MACHINE FAULT) meter since last occurrence)
The machine monitor retains the data for problems a Failure codes for problems that are still
that occurred in the mechanical system in the past existing are shown on a flashing display.
as failure history. They can be displayed as fol- a Refer to failure code table of operator
lows. mode for details of displayed failure
codes.
1. Selection of the service menu a Note that with the failure history display
Select mechanical system failure history dis- function and failure code display function
play function (MACHINE FAULT) in the service (operator mode) for the mechanical sys-
menu selection screen. tem, the displayed data are partially differ-
a The total number of failure history data ent.
items recorded in memory is displayed in a If the fault history is not recorded, "-" is
the [* *] portion. displayed on the display section of 1/A/2/
3/4.
28 HM400-2
30 Testing and adjusting SEN00918-01
[11] Real time monitoring function (REAL-TIME a Monitoring system and function to be
MONITOR) displayed:
The machine monitor can monitor the condition of
No. Display System and function
the machine in real time through the signals from
the sensors installed to various parts of the 1 MONITOR PANEL Machine monitor system
machine. 2 TRANSMISSION Transmission controller system
In the real time monitoring function, the following 2 3 ENGINE Engine controller system
types of display can be shown.
4 BRAKE Retarder controller system
q 1 item independent display (for each controller)
q 2 items simultaneous display (code input) 2 items simultaneous monitor-
5 2 ITEMS
ing
1. Selection of the service menu a Display monitoring system and func-
Select real time monitoring function (REAL- tion in the "*" section.
TIME MONITOR) in the service menu selec-
tion screen.
HM400-2 29
SEN00918-01 30 Testing and adjusting
30 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 31
SEN00918-01 30 Testing and adjusting
32 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 33
SEN00918-01 30 Testing and adjusting
34 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 35
SEN00918-01 30 Testing and adjusting
36 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 37
SEN00918-01 30 Testing and adjusting
38 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 39
SEN00918-01 30 Testing and adjusting
40 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 41
SEN00918-01 30 Testing and adjusting
42 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 43
SEN00918-01 30 Testing and adjusting
44 HM400-2
30 Testing and adjusting SEN00918-01
q [U]: To execute the adjustment menu 8) Normal and abnormal results are dis-
q [ > ]: To switch to the next compensa- played for each adjustment, therefore take
tion screen. action depending on the display.
q [ < ]: To switch to the next compensa-
tion screen.
q Compensation menu: AUTO
a The figure shows the state in which
the automatic compensation is
selected, therefore, [AUTO] is indi-
cated in the lower line. \ In the state in
which the manual compensation is
selected, [MANUAL] is indicated in
the lower line.
HM400-2 45
SEN00918-01 30 Testing and adjusting
3. Reset the transmission initial learning and a The current initialization state is dis-
implementation of learning played in the lower line.
a Before carrying out this adjustment item, q Initialization is done: INITIAL STATUS
be sure to implement "2. Transmission q Initialization is not yet done: TUNED
ECMV current adjustment". a If [TUNED] is indicated, proceed to
a Before proceeding to the learning, confirm the next procedure to initialize the
that the transmission oil temperature is at learning data.
the specified temperature referring to "1. a If the resetting operation is to be
Preparing operations for "Adjusting trans- aborted, press [t] switch to return to
mission ECMV electric current". (If adjust- the former screen.
ments are made at temperatures other q [t]: To return to the previous screen
than specified temperature, time lag or
gear shift shock may occur.)
k The learning should be carried out in
an area with a sufficient traveling dis-
tance, paying attention to the sur-
roundings for safety.
1) Select (TUNING) in the service menu
selection screen.
46 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 47
SEN00918-01 30 Testing and adjusting
48 HM400-2
30 Testing and adjusting SEN00918-01
[15] Filter and oil replacement time setting func- a Displayed maintenance item and
tion (MAINTENANCE MONITOR) function:
Machine monitor can set the maintenance intervals
No. Display Maintenance items and functions
for various filters and oil which become the base of
replacement time display for filter and oil. Also the 1 41:FUEL P FILT Fuel pre filter
machine monitor can activate or deactivate the dis- 2 01:ENG OIL Engine oil
play function. 3 02:ENG FILT Engine oil filter
1. Selection of the service menu
4 12:TM OIL Transmission oil
Select the filter and oil replacement time set-
ting function (MAINTENANCE MONITOR) in 5 13:TM FILT Transmission oil filter
the service menu selection screen. 6 03:FUEL FILT Fuel main filter
7 06:CORR RES Corrosion resistor
8 17:BK OIL Brake oil
9 14:BK OIL FILT Brake oil filter
10 16:BK C FILT Brake cooling oil filter
11 04:HYD FILT Hydraulic oil filter
12 11:DIFF OIL Differential oil
13 08:FNL OIL Final drive oil
14 10:HYD OIL Hydraulic oil
15 INITIALIZE Setting default value for all items
Setting validity or invalidity for all
16 ALL ITEMS
items
2. Displaying and selecting the maintenance item
and function a No.1 – 14 are the maintenance items
1) With the service menu selected, press the where the setting is changed by item,
[U] switch to display the maintenance and No.15 – 16 are the functions
item and function selection screen. which allows to change the setting of
q [U]: Conduct the service menu. all items simultaneously.
a Display the item and function in the [*]
section.
HM400-2 49
SEN00918-01 30 Testing and adjusting
50 HM400-2
30 Testing and adjusting SEN00918-01
3) After the activate or deactivate setting the [U] switch to display the all item
screen is displayed, check the present default value setting screen.
setting status and the contents of change. q [U]: Implement the function to set the
Then operate each of the switches [U] default values of all the items.
and [t].
q [U]: Switch to the change confirma-
tion screen
q [t]: To return to the maintenance
i te m an d fu nc ti on s e le ct io n
screen.
q [< ]: Switch to the interval change
screen.
HM400-2 51
SEN00918-01 30 Testing and adjusting
52 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 53
SEN00918-01 30 Testing and adjusting
[16] Operation information display function a There are three types of information
(OPERATION INFO) screen.
Machine monitor can display the fuel consumption
per mile and per time, the fuel consumption per any 4. Information to be displayed (screen 1 – 3)
accumulated time and the travel distance, and the Above: Fuel consumption per km or mile from
fuel consumption during any accumulated time and the last reset point (distance unit is km
its accumulated time. or mile and it depends on the setting of
a Fuel consumption value is the integration of the integrated odometer in the opera-
the targeted injection rate signal which is sent tor mode).
from the engine controller. It is not the mea- Maximum display value:
surement of the actual fuel consumption. 99999.9 L/km (L/mile)
Therefore the displayed fuel consumption is Below: Fuel consumption per time started
used as a guide value. from the last reset point
Maximum display value: 99999.9 L/h
1. Selection of the service menu
Select the operation information display func-
tion (OPERATION INFO) on the service menu
selection screen.
54 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 55
SEN00918-01 30 Testing and adjusting
56 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 57
SEN00918-01 30 Testing and adjusting
6) Make sure that the 7-segment indicator 7) Turn the starting switch to START position
lamp is indicated normally on the for about 3 to 5 seconds, and make sure
KOMTRAX terminal. that the engine does not start.
a If so, the 7-segment indicator lamp will a If the engine starts, re-execute the
indicate characters “d”, “0”, and “–” procedure above from step 1).
repeatedly for 30 seconds after step 5) a Do not return the starting switch to
was ended. OFF position.
a Those characters, even if displayed 8) Turn the starting switch from ACC position
normally, will change to a character to START position again, and make sure
other than hyphen “–”after 30 sec- that the engine starts.
onds or above elapsed. 9) Make sure that the KOMTRAX terminal's
The display may change to a charac- indicator lamps are normally turned on.
ter other than “0” even within 30 sec- a Move on to the next step if you can
onds. check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trou-
ble and reception trouble] is indi-
cated, check if there is any
abnormality on the GPS antenna/
cable or communication antenna/
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Network trouble] is indicated,
check the display of [LED-C4] refer-
ring to “Lamp display of KOMTRAX
terminal”. If the CAN is not recog-
nized, check the CAN harness of the
a As [Normal] is indicated, proceed to KOMTRAX terminal, and then if there
the next step. is any abnormality, repair it and start
a If “–” remains displayed, execute from procedure 1) again.
steps 1) to 5) again.
58 HM400-2
30 Testing and adjusting SEN00918-01
[A]: Normal
[B]: GPS position data detection trou-
ble
[C]: Reception trouble
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
HM400-2 59
SEN00918-01 30 Testing and adjusting
2. Application for the start of use 3. Opening station request of ORBCOMM ter-
a Application for the start of use is made minal
only after the sign-up test on the machine Fill in the necessary matters in the paper of
side is finished. "opening request of ORBCOMM terminal" and
1) Notify to the KOMTRAX operations ad- send KOMTRAX service hotline by fax or mail.
ministrator the following information con-
cerning the machine whose sign-up test
on the machine is completed.
(1) Information on the machine whose
sign-up test on the machine system is
completed (model, model number
and serial number).
(2) Part number and serial number of the
KOMTRAX terminal
(3) Reading of the service meter when
the KOMTRAX terminal is installed
(0.1 h unit)
60 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 61
SEN00918-01 30 Testing and adjusting
62 HM400-2
30 Testing and adjusting SEN00918-01
In the KOMTRAX system, various information and processing details are displayed on the LEDs on the
upper surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the fol-
lowing checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the vehicle bodies should be completed before using
KOMTRAX system.
On the bodies for which these procedures have not been completed yet, all the LEDs for the communication
module are light-off. This is not a defect.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be disconnected or damaged.
q The communication antenna cable should not be broken and be connected normally with the
KOMTRAX terminal.
q The GPS antenna should not be disconnected or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
HM400-2 63
SEN00918-01 30 Testing and adjusting
64 HM400-2
30 Testing and adjusting SEN00918-01
HM400-2 65
SEN00918-01 30 Testing and adjusting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
66 HM400-2
SEN01107-00
HM400-2
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Check before troubleshooting .............................................................................................................. 4
Classification and procedures for troubleshooting ............................................................................... 5
Connector pin Nos. and connection table ............................................................................................ 8
T-boxes and T-adapters table ............................................................................................................ 31
HM400-2 1
SEN01107-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01107-00
HM400-2 3
SEN01107-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01107-00
1. Procedure for troubleshooting to be taken when action code and failure code are displayed on
machine monitor:
If a action code and a failure code are displayed on the machine monitor, carry out the troubleshooting
for the corresponding "Display of code" according to the displayed failure code.
2. When electrical system failure code or mechanical system failure code is recorded in fault his-
tory:
If a action code and a failure code are not displayed on the machine monitor, check for a mechanical
system failure code and an electrical system failure code with the fault history function of the machine
monitor.
If a failure code is recorded, carry out troubleshooting for the corresponding "Display of code" accord-
ing to that code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a A failure code of the mechanical system cannot be deleted.
3. When action code or failure code is not displayed and no failure code is recorded in fault
history:
If a action code or a failure code is not displayed on the machine monitor and no failure code is recorded
in the fault history, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of "Phenomena looking like troubles and troubleshooting Nos.", and then carry out trouble-
shooting corresponding to that phenomenon in the "E mode", "H mode", or "S mode".
HM400-2 5
SEN01107-00 40 Troubleshooting
Troubleshooting
No. Phenomenon looking like trouble Display
E mode H mode S mode
of code
Action code/Failure code
1 Action code and failure code are displayed on machine monitor
When fault history is checked, failure code is displayed in mechanical Accord-
2
system fault history ing to fail-
When fault history is checked, failure code is displayed in electrical ure code
3
system fault history
Phenomena related to engine
4 Starting performance is poor S-1
5 Engine does not start E-1 S-2
6 Engine does not pick up smoothly S-3
7 Engine stops during operations S-4
8 Engine does not rotate smoothly S-5
9 Engine lacks output (or lacks power) S-6
10 Exhaust smoke is black (incomplete combustion) S-7
11 Oil consumption is excessive (or exhaust smoke is blue) S-8
12 Oil becomes contaminated quickly S-9
13 Fuel consumption is excessive S-10
14 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
15 Oil pressure drops S-12
16 Oil level rises (Entry of coolant/fuel) S-13
17 Coolant temperature becomes too high (overheating) S-14
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
20 Preheater does not operate E-2
Phenomena related to power train
21 Machine does not start H-1
22 Travel is not smooth H-2
23 Lockup is not reset H-3
24 Start shock and gear shift shock are abnormally large H-4
25 Gear is not shifted up H-5
26 Travel speed or power is low H-6
27 Start and gearshift time lag is large H-7
28 Torque converter oil temperature is high H-8
29 Torque converter oil temperature is low H-9
Phenomena related to brake
30 Front brake does not work fully H-10
31 Center brake does not work fully H-11
32 Rear brake does not work fully H-12
Phenomena related to steering system
33 Steering wheel is heavy H-13
34 Steering wheel does not move H-14
35 Steering wheel waggle H-15
6 HM400-2
40 Troubleshooting SEN01107-00
Troubleshooting
No. Phenomenon looking like trouble Display
E mode H mode S mode
of code
Phenomena related to dump body
36 Dump body raising speed is low H-16
37 Dump body does not move H-17
38 Hydraulic drift of dump body is large H-18
Phenomena related to machine monitor/panel switch
39 When starting switch is turned ON, machine monitor displays nothing E-3
When starting switch is turned OFF, machine monitor cannot be
40 E-4
operated
41 Alarm buzzer does not sound E-5
Machine monitor does not normally display gauges, caution lamps, and
42 E-6
character display section
43 Display of character display section cannot be changed E-7
44 Power mode selection function does not operate normally E-8
45 AISS function does not operate normally E-9
Right and left differential lock function does not operate normally
46 E-10
(Differential lock-up specification)
47 Interaxle differential lock-up function does not operate normally E-11
48 Display of seat belt caution lamp is abnormal E-12
49 Turn signal lamps and pilot lamps do not operate normally E-13
50 Night lighting is abnormal E-14
51 Backup lamp and backup buzzer operate abnormally E-15
52 Emergency steering system does not operate E-16
HM400-2 7
SEN01107-00 40 Troubleshooting
2 799-601-7020
3 799-601-7030
4 799-601-7040
8 HM400-2
40 Troubleshooting SEN01107-00
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
HM400-2 9
SEN01107-00 40 Troubleshooting
16 799-601-7320
10 HM400-2
40 Troubleshooting SEN01107-00
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
HM400-2 11
SEN01107-00 40 Troubleshooting
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
12 HM400-2
40 Troubleshooting SEN01107-00
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
HM400-2 13
SEN01107-00 40 Troubleshooting
5 799-601-2710
9 799-601-2950
13 799-601-2720
14 HM400-2
40 Troubleshooting SEN01107-00
17 799-601-2730
21 799-601-2740
HM400-2 15
SEN01107-00 40 Troubleshooting
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
16 HM400-2
40 Troubleshooting SEN01107-00
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
HM400-2 17
SEN01107-00 40 Troubleshooting
2 —
— —
9 —
— —
10 799-601-3460
— —
18 HM400-2
40 Troubleshooting SEN01107-00
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
HM400-2 19
SEN01107-00 40 Troubleshooting
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
20 HM400-2
40 Troubleshooting SEN01107-00
4 —
— —
HM400-2 21
SEN01107-00 40 Troubleshooting
799-601-9210
799-601-9210
799-601-9220
799-601-9220
22 HM400-2
40 Troubleshooting SEN01107-00
799-601-9230
799-601-9230
799-601-9240
799-601-9240
HM400-2 23
SEN01107-00 40 Troubleshooting
799-601-9250
799-601-9250
799-601-9260
799-601-9260
24 HM400-2
40 Troubleshooting SEN01107-00
799-601-9270
799-601-9270
799-601-9280
799-601-9280
HM400-2 25
SEN01107-00 40 Troubleshooting
799-601-9290
799-601-9290
26 HM400-2
40 Troubleshooting SEN01107-00
2 799-601-9020
Part No.: 08192-12200 (Normal type) Part No.: 08192-12100 (Normal type)
08192-22200 (Fine wire type) 08192-22100 (Fine wire type)
3 799-601-9030
Part No.: 08192-13200 (Normal type) Part No.: 08192-13100 (Normal type)
08192-23200 (Fine wire type) 08192-23100 (Fine wire type)
4 799-601-9040
Part No.: 08192-14200 (Normal type) Part No.: 08192-14100 (Normal type)
08192-24200 (Fine wire type) 08192-24100 (Fine wire type)
6 799-601-9050
Part No.: 08192-16200 (Normal type) Part No.: 08192-16100 (Normal type)
08192-26200 (Fine wire type) 08192-26100 (Fine wire type)
HM400-2 27
SEN01107-00 40 Troubleshooting
Part No.: 08192-1820! (Normal type) Part No.: 08192-1810! (Normal type)
08192-2820! (Fine wire type) 08192-2810! (FIne wire type)
Part No.: 08192-1920! (Normal type) Part No.: 08192-1910! (Normal type)
08192-2920! (Fine wire type) 08192-2910! (Fine wire type)
28 HM400-2
40 Troubleshooting SEN01107-00
799-601-9010
2
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 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)
HM400-2 29
SEN01107-00 40 Troubleshooting
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
30 HM400-2
40 Troubleshooting SEN01107-00
T-adapter kit
Number of pins
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
Out of kit
Distinction
Part No. Part name
symbol
HM400-2 31
SEN01107-00 40 Troubleshooting
T-adapter kit
Number of pins
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
Out of kit
Distinction
Part No. Part name
symbol
32 HM400-2
40 Troubleshooting SEN01107-00
T-adapter kit
Number of pins
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
Out of kit
Distinction
Part No. Part name
symbol
HM400-2 33
SEN01107-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
34 HM400-2
SEN01262-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, General
Troubleshooting by failure code, General ....................................................................................................... 2
Failure codes table............................................................................................................................... 2
Before troubleshooting by failure code............................................................................................... 10
Information in troubleshooting table ................................................................................................... 18
HM400-2 1
SEN01262-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01262-00
HM400-2 3
SEN01262-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01262-00
HM400-2 5
SEN01262-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01262-00
DX12KY Hot short circuit of front wheels electromagnetic pro- BK E03 Electrical
portional pressure reducing valve output circuit system
DX12MA Front wheels electromagnetic proportional pressure BK E03 Electrical
reducing valve failure 2 system
DX13KA Disconnection of Dump EPC valve output circuit TM E03 Electrical
system
Electrical Troubleshooting
DX13KB Ground fault of Dump EPC valve output circuit TM E03 system by failure code,
Electrical Part 7
DX13KY Hot short circuit of Dump EPC valve output circuit TM E03 system SEN01114-00
Rear wheels differential lock-up command output Electrical
DX14KZ system failure BK E03 system
HM400-2 7
SEN01262-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01262-00
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable equipment:
Applicable equipment indicates in which controller system the failure has occurred.
MON : Machine monitor system
ENG : Engine controller system
TM : Transmission controller system
BK : Retarder controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
HM400-2 9
SEN01262-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01262-00
HM400-2 11
SEN01262-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01262-00
HM400-2 13
SEN01262-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01262-00
HM400-2 15
SEN01262-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01262-00
HM400-2 17
SEN01262-00 40 Troubleshooting
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do not
(1) Method of indicating connector No. and handling of T-
indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
18 HM400-2
40 Troubleshooting SEN01262-00
HM400-2 19
SEN01262-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
20 HM400-2
SEN01108-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 1 .......................................................................................................... 3
Failure code [1500L0] Double engagement ......................................................................................... 3
Failure code [15B0NX] Transmission oil filter: Clogged ....................................................................... 4
Failure code [15F0KM] R o F shifting abuse 1.................................................................................... 6
Failure code [15F0MB] R o F shifting abuse 2.................................................................................... 6
Failure code [15F7KM] Transmission forward clutch abuse ............................................................... 7
Failure code [15G0MW] Trouble in reverse clutch system (Slip) ......................................................... 8
Failure code [15G7KM] Transmission reverse clutch abuse.............................................................. 10
Failure code [15H0MW] Trouble in Hi clutch system (Slip) ................................................................ 12
Failure code [15J0MW] Trouble in Lo clutch system (Slip) ............................................................... 14
Failure code [15K0MW] Trouble in 1st clutch system (Slip)............................................................... 16
Failure code [15L0MW] Trouble in 2nd clutch system (Slip) .............................................................. 18
Failure code [15M0MW] Trouble in 3rd clutch system (Slip).............................................................. 20
Failure code [15SBL1] Trouble in reverse clutch pressure control valve ........................................ 22
Failure code [15SBMA] Trouble in reverse clutch pressure control valve ..................................... 26
Failure code [15SCL1] Trouble in Hi clutch pressure control valve ................................................. 28
HM400-2 1
SEN01108-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01108-00
HM400-2 3
SEN01108-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01108-00
HM400-2 5
SEN01108-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01108-00
HM400-2 7
SEN01108-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 9
SEN01108-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01108-00
HM400-2 11
SEN01108-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 13
SEN01108-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 15
SEN01108-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 17
SEN01108-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 19
SEN01108-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 21
SEN01108-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01108-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 23
SEN01108-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01108-00
HM400-2 25
SEN01108-00 40 Troubleshooting
26 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 27
SEN01108-00 40 Troubleshooting
28 HM400-2
40 Troubleshooting SEN01108-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 29
SEN01108-00 40 Troubleshooting
30 HM400-2
40 Troubleshooting SEN01108-00
HM400-2 31
SEN01108-00 40 Troubleshooting
32 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 33
SEN01108-00 40 Troubleshooting
34 HM400-2
40 Troubleshooting SEN01108-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 35
SEN01108-00 40 Troubleshooting
36 HM400-2
40 Troubleshooting SEN01108-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 37
SEN01108-00 40 Troubleshooting
38 HM400-2
40 Troubleshooting SEN01108-00
HM400-2 39
SEN01108-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
40 HM400-2
SEN01109-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 2
Troubleshooting by failure code, Part 2 .......................................................................................................... 3
Failure code [15SEL1] Trouble in 1st clutch pressure control valve .................................................. 3
Failure code [15SEMA] Trouble in 1st clutch pressure control valve ................................................ 6
Failure code [15SFL1] Trouble in 2nd clutch pressure control valve ................................................. 8
Failure code [15SFMA] Trouble in 2nd clutch pressure control valve ............................................. 12
Failure code [15SGL1] Trouble in 3rd clutch pressure control valve ................................................ 14
Failure code [15SGMA] Trouble in 3rd clutch pressure control valve ............................................. 18
Failure code [15SJMA] Trouble in lockup clutch pressure control valve ......................................... 20
Failure code [15SKMA] Trouble in interaxle differential lock clutch pressure control valve ............ 22
Failure code [2A62L1] Trouble in front wheel differential lock pressure control valve 2 ..................... 24
Failure code [2A62LH] Trouble in front wheel differential lock pressure control valve 1 .................... 26
Failure code [2B62L1] Trouble in rear wheel differential lock pressure control valve 2 ...................... 28
Failure code [2B62LH] Trouble in rear wheel differential lock pressure control valve 1 ..................... 30
Failure code [2C4MNX] Clogging of retarder cooling oil filter ............................................................. 32
Failure code [2F00KM] Dragging of parking brake ............................................................................. 34
Failure code [2G42ZG] Lowering of accumulator oil pressure (front) ................................................. 36
HM400-2 1
SEN01109-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 3
SEN01109-00 40 Troubleshooting
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
4 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 5
SEN01109-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01109-00
Table 1
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 7
SEN01109-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01109-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 9
SEN01109-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 11
SEN01109-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01109-00
Table 1
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 13
SEN01109-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01109-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 15
SEN01109-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 17
SEN01109-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01109-00
Table 1
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 19
SEN01109-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 21
SEN01109-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01109-00
Circuit diagram related to interaxle differential lock clutch ECMV fill switch
HM400-2 23
SEN01109-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 25
SEN01109-00 40 Troubleshooting
26 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 27
SEN01109-00 40 Troubleshooting
28 HM400-2
40 Troubleshooting SEN01109-00
Circuit diagram related to differential lock oil pressure switches (center and rear)
HM400-2 29
SEN01109-00 40 Troubleshooting
Contents of • When signal is output to rear differential lock solenoid circuit 30 seconds or more after engine is
trouble started, signal from differential lock oil pressure switch is kept OFF.
Action of • None in particular.
controller
Problem that
appears on • There is no particular effect on machine.
machine
Related • Method of reproducing failure code: Turn starting switch ON + Set right and left differential lock
information switches to upper or lower position + Press right and left differential lock pedals
5 Defective hydraulic and If causes 1 – 4 are not detected, carry out troubleshooting for
mechanical systems hydraulic and mechanical systems.
30 HM400-2
40 Troubleshooting SEN01109-00
Circuit diagram related to differential lock oil pressure switches (center and rear)
HM400-2 31
SEN01109-00 40 Troubleshooting
32 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 33
SEN01109-00 40 Troubleshooting
34 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 35
SEN01109-00 40 Troubleshooting
36 HM400-2
40 Troubleshooting SEN01109-00
Failure code [989D00] Rear section tipping over alarm (Raising operation
on slope) 1
Action code Failure code Rear section tipping over alarm (Raising operation on slope)
Trouble
– 989D00 (Machine monitor system)
Contents of
• While machine is slanting more than 15°, dump body is raised.
trouble
Action of
• Turns pitch angle caution lamp ON and sounds alarm buzzer.
machine monitor
Problem that
appears on • If dump body is raised as it is, machine may tip over.
machine
• Pitch angle and pitch angle signal can be checked with monitoring function.
Related (Monitoring code: TRANSMISSION - ANGLE SENSOR - 32900)
information • Information of operation of rear section tipping over alarm is received from transmission controller
through network.
HM400-2 37
SEN01109-00 40 Troubleshooting
38 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 39
SEN01109-00 40 Troubleshooting
40 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 41
SEN01109-00 40 Troubleshooting
42 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 43
SEN01109-00 40 Troubleshooting
44 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 45
SEN01109-00 40 Troubleshooting
46 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 47
SEN01109-00 40 Troubleshooting
48 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 49
SEN01109-00 40 Troubleshooting
50 HM400-2
40 Troubleshooting SEN01109-00
HM400-2 51
SEN01109-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
52 HM400-2
SEN01110-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 3
Troubleshooting by failure code, Part 3 .......................................................................................................... 4
Failure code [CA111] Trouble in engine controller ................................................................................ 4
Failure code [CA115] Trouble in engine Ne and Bkup speed sensors ................................................. 6
Failure code [CA122] Abnormally high charge pressure ...................................................................... 8
Failure code [CA123] Abnormally low charge pressure...................................................................... 10
Failure code [CA131] Abnormally high throttle sensor signal ............................................................. 12
Failure code [CA132] Abnormally low throttle sensor signal .............................................................. 14
Failure code [CA135] Abnormally high engine oil pressure................................................................ 16
Failure code [CA141] Abnormally low engine oil pressure ................................................................. 18
Failure code [CA144] Abnormally high coolant temperature .............................................................. 20
Failure code [CA145] Abnormally low coolant temperature................................................................ 22
Failure code [CA153] Abnormally high charge temperature ............................................................... 24
Failure code [CA154] Abnormally low charge temperature ................................................................ 26
Failure code [CA187] Abnormally low voltage in sensor power supply 2 ........................................... 27
Failure code [CA221] Abnormally high ambient pressure .................................................................. 28
Failure code [CA222] Abnormally low ambient pressure .................................................................... 30
HM400-2 1
SEN01110-00 40 Troubleshooting
Failure code [CA227] Abnormally high voltage in sensor power supply 2 .......................................... 32
Failure code [CA234] Engine overspeed ............................................................................................ 34
Failure code [CA238] Trouble in Ne speed sensor power supply ....................................................... 36
Failure code [CA263] Abnormally high fuel temperature .................................................................... 38
Failure code [CA265] Abnormally low fuel temperature...................................................................... 40
Failure code [CA271] Short circuit in PCV1 ........................................................................................ 41
Failure code [CA272] Disconnection in PCV1 .................................................................................... 42
Failure code [CA273] Short circuit in PCV2 ........................................................................................ 43
Failure code [CA274] Disconnection in PCV2 .................................................................................... 44
Failure code [CA322] Disconnection or short circuit in injector #1 (L #1) ........................................... 45
Failure code [CA323] Disconnection or short circuit in injector #5 (L #5) ........................................... 46
Failure code [CA324] Disconnection or short circuit in injector #3 (L #3) ........................................... 47
Failure code [CA325] Disconnection or short circuit in injector #6 (L #6) ........................................... 48
Failure code [CA331] Disconnection or short circuit in injector #2 (L #2) ........................................... 49
Failure code [CA332] Disconnection or short circuit in injector #4 (L #4) ........................................... 50
Failure code [CA342] Matching error in engine controller data........................................................... 51
Failure code [CA351] Trouble in injector drive circuit.......................................................................... 52
Failure code [CA352] Abnormally low voltage in sensor power supply 1 ........................................... 54
Failure code [CA386] Abnormally high voltage in sensor power supply 1 .......................................... 56
2 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 3
SEN01110-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 5
SEN01110-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 7
SEN01110-00 40 Troubleshooting
Problem that
• Acceleration performance of engine lowers.
appears on
• More black smoke is produced during acceleration.
machine
Related
information
8 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 9
SEN01110-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 11
SEN01110-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 13
SEN01110-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 15
SEN01110-00 40 Troubleshooting
Problem that
appears on
machine
Related • Condition of engine oil pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - ENGINE OIL PRESS - 37201)
16 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 17
SEN01110-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 19
SEN01110-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 21
SEN01110-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 23
SEN01110-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 25
SEN01110-00 40 Troubleshooting
26 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 27
SEN01110-00 40 Troubleshooting
Problem that
appears on • Engine output lowers.
machine
Related • Condition of ambient pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - AMBIENT PRESS - 37401)
1 Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
ply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
PAMB Voltage
Defective ambient pressure Between (1) – (2) Power supply 4.75 – 5.25 V
2 sensor (Internal defect)
Between (3) – (2) Signal
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshoot-
ing without turning starting switch ON.
Disconnection in wiring har- Wiring harness between ENG (female) (37) Resis-
– PAMB (female) (1) tance Max. 1 z
ness (Disconnection in wiring
3 or defective contact in con-
Wiring harness between ENG (female) (38) Resis-
nector) – PAMB (female) (2) tance Max. 1 z
28 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 29
SEN01110-00 40 Troubleshooting
30 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 31
SEN01110-00 40 Troubleshooting
Contents of • Voltage in sensor power supply 2 (5V) circuit of engine controller is abnormally high.
trouble
• Bkup speed sensor operates with Ne speed sensor signal.
• Oil pressure sensor fixes oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
• Ambient pressure sensor fixes ambient pressure to default value (52.44 kPa {0.53 kg/cm2}) and
Action of continues operation.
controller • Charge pressure sensor fixes charge pressure to 400 kPa {4.08 kg/cm2} and continues operation.
• EGR inlet pressure sensor fixes EGR inlet pressure to default value (102 kPa {1.05 kg/cm2}) and
limits output and continues operation.
• EGR valve lift sensor limits output and closes EGR valve and bypass valve.
• Bypass valve lift sensor limits output and closes EGR valve and bypass valve.
Problem that
appears on • Engine output lowers.
machine
Related
information
32 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 33
SEN01110-00 40 Troubleshooting
34 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 35
SEN01110-00 40 Troubleshooting
36 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 37
SEN01110-00 40 Troubleshooting
38 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 39
SEN01110-00 40 Troubleshooting
40 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 41
SEN01110-00 40 Troubleshooting
42 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 43
SEN01110-00 40 Troubleshooting
44 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 45
SEN01110-00 40 Troubleshooting
46 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 47
SEN01110-00 40 Troubleshooting
48 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 49
SEN01110-00 40 Troubleshooting
50 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 51
SEN01110-00 40 Troubleshooting
52 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 53
SEN01110-00 40 Troubleshooting
54 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 55
SEN01110-00 40 Troubleshooting
56 HM400-2
40 Troubleshooting SEN01110-00
HM400-2 57
SEN01110-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
58 HM400-2
SEN01111-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 4
Troubleshooting by failure code, Part 4 .......................................................................................................... 4
Failure code [CA431] Trouble in idle validation switch......................................................................... 4
Failure code [CA432] Trouble in idle validation process ...................................................................... 6
Failure code [CA441] Abnormally low voltage in power supply ........................................................... 6
Failure code [CA442] Abnormally high voltage in power supply .......................................................... 7
Failure code [CA449] Abnormally high common rail pressure 2 .......................................................... 7
Failure code [CA451] Abnormally high common rail pressure ............................................................. 8
Failure code [CA452] Abnormally low common rail pressure ............................................................ 10
Failure code [CA553] Abnormally high common rail pressure 1 ........................................................ 10
Failure code [CA554] In-range error in common rail pressure sensor ................................................11
Failure code [CA559] Supply pump low pressure 1 ........................................................................... 13
Failure code [CA689] Trouble in engine Ne speed sensor................................................................. 16
Failure code [CA731] Phase error in engine Bkup speed sensor ...................................................... 18
Failure code [CA757] Loss of all data in engine controller ................................................................. 18
Failure code [CA778] Trouble in engine Bkup speed sensor ............................................................. 20
Failure code [CA1117] Loss of partial data in engine controller ......................................................... 22
HM400-2 1
SEN01111-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 3
SEN01111-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01111-00
Fig. 1
HM400-2 5
SEN01111-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 7
SEN01111-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01111-00
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard or start engine and carry out troubleshooting.
value in normal 6 Defective engine controller ENG Voltage
state Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
HM400-2 9
SEN01111-00 40 Troubleshooting
1
Failure code [CA553] Abnormally high common rail pressure 1 1
Action code Failure code Abnormally high common rail pressure 1
Trouble
E03 CA553 (Engine controller system)
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine output lowers.
machine
Related • Common rail pressure can be checked with monitoring function.
information (Monitoring code: ENGINE - RAIL PRESS - 36400)
10 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 11
SEN01111-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 13
SEN01111-00 40 Troubleshooting
B. Check with machine monitor (02 Fault history, 01 monitoring, and 09 reduced cylinder mode operation) Good NG
3 Check of failure code / / / /
Check of monitoring information
Standard value Measured
Code Displayed item Checking condition ISO unit Good NG
(Reference value) value
Low idle r/min 700 – 750
01002 Engine speed High idle r/min 2,200 – 2,250
Torque converter stall r/min 2,000
Final accelerator Low idle % 0
31706
position High idle % 100
Final fuel injection
18600 rate command Torque converter stall mg/st — — —
(by weight)
4
Final common rail
36200 Torque converter stall MPa — — —
pressure command
Common rail pres-
36400 Torque converter stall MPa — — —
sure
Low idle CA — — —
Final injection tim-
36300 High idle CA — — —
ing command
Torque converter stall CA — — —
36500 Boost pressure Torque converter stall kPa — — —
Engine coolant tem-
04107 Low idle °C — — —
perature
14200 Fuel temperature Low idle °C — — —
Check of reduced cylinder mode operation (Engine speed)
Standard value Measured
Setting Reduced cylinder Checking condition ISO unit Good NG
(Reference value) value
No. 1 cylinder Low idle r/min — — —
5 No. 2 cylinder Low idle r/min — — —
Reduce No. 3 cylinder Low idle r/min — — —
each
cylinder No. 4 cylinder Low idle r/min — — —
No. 5 cylinder Low idle r/min — — —
No. 6 cylinder Low idle r/min — — —
14 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 15
SEN01111-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 17
SEN01111-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 19
SEN01111-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 21
SEN01111-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 23
SEN01111-00 40 Troubleshooting
Failure code [CA1626] Short circuit in bypass valve solenoid drive circuit1
Action code Failure code Short circuit in bypass valve solenoid drive circuit
Trouble
E03 CA1626 (Engine controller system)
Contents of
• There is short circuit in drive circuit of bypass valve solenoid.
trouble
Action of • Limits engine output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
appears on • Engine output lowers.
machine
Related
information
24 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 25
SEN01111-00 40 Troubleshooting
26 HM400-2
40 Troubleshooting SEN01111-00
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for "S-
and standard 12 Oil pressure lowers" in S mode.
value in normal Defective oil pump for Oil pump and relief valve for bypass valve circuit may be defective.
3
state bypass valve Check it directly.
Defective oil feed piping for Oil feed piping for bypass valve circuit may be defective. Check it
4
bypass valve directly.
Defective oil return piping for Oil return piping for bypass valve circuit may be defective. Check it
5
bypass valve directly.
Mechanical section of bypass valve may be defective. Check it
6 Defective bypass valve
directly.
If causes 1 – 6 are not detected, engine controller may be defec-
7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
HM400-2 27
SEN01111-00 40 Troubleshooting
28 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 29
SEN01111-00 40 Troubleshooting
Failure code [CA1631] Abnormally high signal in bypass valve lift sensor1
Action code Failure code Abnormally high signal in bypass valve lift sensor
Trouble
E03 CA1631 (Engine controller system)
Contents of
• Signal voltage in bypass valve lift sensor circuit is abnormally high.
trouble
Action of • Limits engine output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
appears on • Engine output lowers.
machine
Related • Condition of bypass valve lift sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - BPS VALVE POS - 18201)
30 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 31
SEN01111-00 40 Troubleshooting
32 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 33
SEN01111-00 40 Troubleshooting
34 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 35
SEN01111-00 40 Troubleshooting
Failure code [CA1642] Abnormally low signal in EGR inlet pressure sensor1
Action code Failure code Abnormally low signal in EGR inlet pressure sensor
Trouble
E01 CA1642 (Engine controller system)
Contents of
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally low.
trouble
Action of • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller • Limits engine output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related
information
36 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 37
SEN01111-00 40 Troubleshooting
Failure code [CA1653] Abnormally high signal in EGR inlet pressure sensor1
Action code Failure code Abnormally high signal in EGR inlet pressure sensor
Trouble
E01 CA1653 (Engine controller system)
Contents of
• Signal voltage in EGR valve inlet pressure sensor circuit is abnormally high.
trouble
Action of • Sets EGR valve inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller • Limits engine output and continues operation.
Problem that
appears on • Engine output lowers.
machine
Related • Condition of EGR valve inlet pressure sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - EGR IN PRESS-A - 18001)
38 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 39
SEN01111-00 40 Troubleshooting
Failure code [CA2185] Abnormally high voltage in throttle sensor power supply1
Action code Failure code Abnormally high voltage in throttle sensor power supply
Trouble
E03 CA2185 (Engine controller system)
Contents of
• Voltage in throttle sensor power supply (5V) circuit is abnormally high.
trouble
Action of
• Sets throttle position with signals other than throttle sensor signal and continues operation.
controller
Problem that
appears on
machine
Related
information
40 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 41
SEN01111-00 40 Troubleshooting
Failure code [CA2186] Abnormally low voltage in throttle sensor power supply1
Action code Failure code Abnormally low voltage in throttle sensor power supply
Trouble
E03 CA2186 (Engine controller system)
Contents of
• Voltage in throttle sensor power supply (5V) circuit of engine controller is abnormally low.
trouble
Action of
• Sets throttle position with signals other than throttle sensor signal and continues operation.
controller
Problem that
appears on
machine
Related
information
1
Failure code [CA2249] Low pressure in supply pump 2 1
Action code Failure code Low pressure in supply pump 2
Trouble
E03 CA2249 (Engine controller system)
Contents of
• Very low pressure (level 2) is detected in supply pump.
trouble
Action of
• Limits common rail pressure.
controller
Problem that
appears on • Engine output lowers.
machine
Related
information
42 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 43
SEN01111-00 40 Troubleshooting
Failure code [CA2271] Abnormally high signal voltage in EGR valve lift sensor1
Action code Failure code Abnormally high signal voltage in EGR valve lift sensor
Trouble
E03 CA2271 (Engine controller system)
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally high.
trouble
Action of • Limits engine output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
appears on • Engine output lowers.
machine
Related • Condition of EGR valve lift sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - EGR VALVE POS - 18101)
44 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 45
SEN01111-00 40 Troubleshooting
Failure code [CA2272] Abnormally low signal voltage in EGR valve lift sensor 1
Action code Failure code Abnormally low signal voltage in EGR valve lift sensor
Trouble
E03 CA2272 (Engine controller system)
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally low.
trouble
Action of • Limits engine output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
appears on • Engine output lowers.
machine
Related • Condition of EGR valve lift sensor signal can be checked with monitoring function.
information (Monitoring code: ENGINE - EGR VALVE POS - 18101)
46 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 47
SEN01111-00 40 Troubleshooting
Failure code [CA2351] Short circuit in EGR valve solenoid drive circuit1
Action code Failure code Short circuit in EGR valve solenoid drive circuit
Trouble
E03 CA2351 (Engine controller system)
Contents of
• There is short circuit in EGR valve solenoid drive circuit.
trouble
Action of • Limits engine output and continues operation.
controller • Closes EGR valve and bypass valve.
Problem that
appears on • Engine output lowers.
machine
Related
information
48 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 49
SEN01111-00 40 Troubleshooting
1
Failure code [CA2555] Disconnection in intake air heater relay 1
Action code Failure code Disconnection in intake air heater relay
Trouble
E01 CA2555 (Engine controller system)
Contents of
• There is disconnection in intake air heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Engine coolant temperature can be checked with monitoring function.
information (Monitoring code: ENGINE - COOLANT - TEMP - 04104)
50 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 51
SEN01111-00 40 Troubleshooting
52 HM400-2
40 Troubleshooting SEN01111-00
HM400-2 53
SEN01111-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
54 HM400-2
SEN01112-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 5
Troubleshooting by failure code, Part 5 .......................................................................................................... 3
Failure code [DAF9KM] Wrong connection of connector...................................................................... 3
Failure code [DAFRKR] Trouble in CAN communication (machine monitor)........................................ 4
Failure code [DAQ0KK] Lowering of source voltage ............................................................................ 6
Failure code [DAQ0KT] Trouble in non-volatile memory ...................................................................... 8
Failure code [DAQ2KK] Trouble in solenoid power supply system..................................................... 10
Failure code [DAQ9KQ] Disagreement of model selection (Transmission controller) ........................ 12
Failure code [DAQRKR] Trouble in CAN communication (Transmission controller)........................... 14
Failure code [DAQRMA] Disagreement of option setting (Transmission controller) ........................... 16
Failure code [DB10KT] Trouble in non-volatile memory ..................................................................... 16
Failure code [DB12KK] Trouble in solenoid power supply system .................................................... 18
Failure code [DB13KK] Lowering of battery direct voltage ................................................................. 20
Failure code [DB19KQ] Disagreement of model selection (Retarder controller) ................................ 22
Failure code [DB1QMA] Disagreement of option setting (Retarder controller) ................................... 22
Failure code [DB1RKR] Trouble in CAN communication (Retarder controller)................................... 24
Failure code [DB2RKR] Trouble in CAN communication (Engine controller) ..................................... 26
HM400-2 1
SEN01112-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 3
SEN01112-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 5
SEN01112-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 7
SEN01112-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 9
SEN01112-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 11
SEN01112-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 13
SEN01112-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 15
SEN01112-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 17
SEN01112-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 19
SEN01112-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 21
SEN01112-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 23
SEN01112-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 25
SEN01112-00 40 Troubleshooting
26 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 27
SEN01112-00 40 Troubleshooting
28 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 29
SEN01112-00 40 Troubleshooting
30 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 31
SEN01112-00 40 Troubleshooting
32 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 33
SEN01112-00 40 Troubleshooting
34 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 35
SEN01112-00 40 Troubleshooting
36 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 37
SEN01112-00 40 Troubleshooting
38 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 39
SEN01112-00 40 Troubleshooting
40 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 41
SEN01112-00 40 Troubleshooting
42 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 43
SEN01112-00 40 Troubleshooting
44 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 45
SEN01112-00 40 Troubleshooting
46 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 47
SEN01112-00 40 Troubleshooting
48 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 49
SEN01112-00 40 Troubleshooting
50 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 51
SEN01112-00 40 Troubleshooting
52 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 53
SEN01112-00 40 Troubleshooting
54 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 55
SEN01112-00 40 Troubleshooting
56 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 57
SEN01112-00 40 Troubleshooting
58 HM400-2
40 Troubleshooting SEN01112-00
HM400-2 59
SEN01112-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
60 HM400-2
SEN01113-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 6
Troubleshooting by failure code, Part 6 .......................................................................................................... 4
Failure code [DGT1KX] Short circuit in torque converter oil temperature sensor system..................... 4
Failure code [DHT5KX] Disconnection, ground fault, or short circuit in torque converter oil pressure
sensor system.................................................................................................................................. 6
Failure code [DHT5L6] Trouble in torque converter oil pressure sensor .............................................. 8
Failure code [DHU2KX] Trouble in accumulator oil pressure sensor (front) system........................... 10
Failure code [DHU3KX] Trouble in accumulator oil pressure sensor (rear) system ........................... 12
Failure code [DJF1KA] Disconnection in fuel level sensor system ..................................................... 14
Failure code [DK51L5] Trouble in manual retarder potentiometer and RVS ...................................... 16
Failure code [DK52KX] Trouble in dump lever potentiometer 1.......................................................... 18
Failure code [DK53L8] Trouble in dump lever potentiometer 2 .......................................................... 20
Failure code [DK54KX] Trouble in dump positioner sensor ................................................................ 22
Failure code [DKH0KX] Pitch angle sensor signal out of range ......................................................... 24
Failure code [DLF1KA] Disconnection in transmission input shaft speed sensor system .................. 26
Failure code [DLF1LC] Trouble in transmission input shaft speed sensor ......................................... 27
Failure code [DLF2KA] Disconnection in transmission intermediate shaft speed sensor system ...... 28
HM400-2 1
SEN01113-00 40 Troubleshooting
Failure code [DLF2LC] Disconnection in transmission intermediate shaft speed sensor system....... 29
Failure code [DLF4KA] Disconnection in transmission differential speed sensor system .................. 30
Failure code [DLT3KA] Disconnection in transmission output shaft speed sensor system................. 31
Failure code [DV00KB] Short circuit in buzzer output circuit .............................................................. 32
Failure code [DW72KZ] Trouble (Disconnection or ground fault) in kick-out solenoid output
system ........................................................................................................................................... 34
Failure code [DW73KZ] Trouble in dump selector valve output system ............................................. 36
Failure code [DW78KZ] Trouble in rear wheel BCV command output system ................................... 38
Failure code [DW79KZ] Trouble in front wheel BCV command output system................................... 40
Failure code [DX11K4] Trouble in rear wheel proportional solenoid pressure reducing valve 1 ......... 42
Failure code [DX11KA] Disconnection in output circuit of rear wheel proportional solenoid pressure
reducing valve................................................................................................................................ 44
Failure code [DX11KB] Ground fault in output circuit of rear wheel proportional solenoid pressure
reducing valve................................................................................................................................ 46
Failure code [DX11KY] Hot short in output circuit of rear wheel proportional solenoid pressure
reducing valve................................................................................................................................ 48
Failure code [DX11MA] Trouble in rear wheel proportional solenoid pressure reducing valve 2 ........ 50
Failure code [DX12K4] Trouble in front wheel proportional solenoid pressure reducing valve 1........ 52
Failure code [DX12KA] Disconnection in output circuit of front wheel proportional solenoid pressure
reducing valve................................................................................................................................ 54
Failure code [DX12KB] Ground fault in output circuit of front wheel proportional solenoid pressure
reducing valve................................................................................................................................ 56
Failure code [DX12KY] Hot short in output circuit of front wheel proportional solenoid pressure
reducing valve................................................................................................................................ 58
Failure code [DX12MA] Trouble in front wheel proportional solenoid pressure reducing valve 2....... 60
2 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 3
SEN01113-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 5
SEN01113-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 7
SEN01113-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 9
SEN01113-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01113-00
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 5 Defective retarder controller BRC1 Voltage
state Between (16) – (21) Power source 20 – 30 V
Between (7) – (21) Signal 0.5 – 4.5 V
HM400-2 11
SEN01113-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01113-00
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 5 Defective retarder controller BRC1 Voltage
state Between (16) – (21) Power source 20 – 30 V
Between (1) – (21) Signal 0.5 – 4.5 V
HM400-2 13
SEN01113-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 15
SEN01113-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 17
SEN01113-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 19
SEN01113-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 21
SEN01113-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 23
SEN01113-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 25
SEN01113-00 40 Troubleshooting
26 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 27
SEN01113-00 40 Troubleshooting
28 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 29
SEN01113-00 40 Troubleshooting
30 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 31
SEN01113-00 40 Troubleshooting
32 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 33
SEN01113-00 40 Troubleshooting
34 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 35
SEN01113-00 40 Troubleshooting
36 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 37
SEN01113-00 40 Troubleshooting
38 HM400-2
40 Troubleshooting SEN01113-00
Circuit diagram related to brake cooling oil control valve (rear) solenoid
HM400-2 39
SEN01113-00 40 Troubleshooting
40 HM400-2
40 Troubleshooting SEN01113-00
Circuit diagram related to brake cooling oil control valve (front) solenoid
HM400-2 41
SEN01113-00 40 Troubleshooting
42 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 43
SEN01113-00 40 Troubleshooting
44 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 45
SEN01113-00 40 Troubleshooting
46 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 47
SEN01113-00 40 Troubleshooting
48 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 49
SEN01113-00 40 Troubleshooting
50 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 51
SEN01113-00 40 Troubleshooting
52 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 53
SEN01113-00 40 Troubleshooting
54 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 55
SEN01113-00 40 Troubleshooting
56 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 57
SEN01113-00 40 Troubleshooting
58 HM400-2
40 Troubleshooting SEN01113-00
HM400-2 59
SEN01113-00 40 Troubleshooting
60 HM400-2
40 Troubleshooting SEN01113-00
Circuit diagram related to retarder oil pressure switch (front) and retarder proportional pressure
reducing valve (front)
HM400-2 61
SEN01113-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
62 HM400-2
SEN01114-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 7
Troubleshooting by failure code, Part 7 .......................................................................................................... 4
Failure code [DX13KA] Disconnection in output circuit of dump EPC valve ........................................ 4
Failure code [DX13KB] Ground fault in output circuit of dump EPC valve........................................... 6
Failure code [DX13KY] Hot short in output circuit of dump EPC valve ................................................ 8
Failure code [DX14KZ] Trouble in rear wheel differential lock command output system ................... 10
Failure code [DX15KZ] Trouble in front wheel differential lock command output system .................. 12
Failure code [DXH0KA] Disconnection in output circuit of interaxle differential lock clutch solenoid . 14
Failure code [DXH0KB] Ground fault in output circuit of interaxle differential lock clutch solenoid.... 16
Failure code [DXH0KY] Hot short in output circuit of interaxle differential lock clutch solenoid ......... 18
Failure code [DXH1KA] Disconnection in output circuit of lockup clutch solenoid ............................. 19
Failure code [DXH1KB] Ground fault in output circuit of lockup clutch solenoid................................ 20
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid ..................................... 22
Failure code [DXH2KA] Disconnection in output circuit of Hi clutch solenoid .................................... 24
Failure code [DXH2KB] Ground fault in output circuit of Hi clutch ECMV solenoid valve .................. 26
Failure code [DXH2KY] Hot short in output circuit of Hi clutch ECMV solenoid valve ....................... 28
Failure code [DXH3KA] Disconnection in output circuit of Lo clutch solenoid ................................... 32
HM400-2 1
SEN01114-00 40 Troubleshooting
Failure code [DXH3KB] Ground fault in output circuit of Lo clutch ECMV solenoid valve.................. 34
Failure code [DXH3KY] Hot short in output circuit of Lo clutch ECMV solenoid valve....................... 36
Failure code [DXH4KA] Disconnection in output circuit of 1st clutch solenoid................................... 40
Failure code [DXH4KB] Ground fault in output circuit of 1st clutch ECMV solenoid valve................. 42
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV solenoid valve ...................... 44
2 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 3
SEN01114-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 5
SEN01114-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 7
SEN01114-00 40 Troubleshooting
Failure code [DX13KY] Hot short in output circuit of dump EPC valve 1
Action code Failure code Hot short in output circuit of dump EPC valve
Trouble
E03 DX13KY (Transmission controller system)
Contents of
• When output to dump EPC valve is turned OFF, some current flows.
trouble
Action of • Turns output to dump selector valve OFF.
controller • Turns output to dump EPC valve OFF.
Problem that
appears on
machine
• Output current to dump EPC valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - HOIST EPC DIR - 45601)
information
• Method of reproducing failure code: Turn starting switch ON.
8 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 9
SEN01114-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 11
SEN01114-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 13
SEN01114-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 15
SEN01114-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 17
SEN01114-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 19
SEN01114-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 21
SEN01114-00 40 Troubleshooting
Failure code [DXH1KY] Hot short in output circuit of lockup clutch solenoid1
Action code Failure code Hot short in output circuit of lockup clutch solenoid
Trouble
E03 DXH1KY (Transmission controller system)
Contents of
• When output to lockup clutch solenoid is turned OFF, some current flows.
trouble
Action of
• Keeps current gear speed and turns lockup system OFF.
controller
Problem that • Gear cannot be shifted.
appears on • Lockup system is kept OFF.
machine • If gearshift lever is set in "N", machine cannot restart until it stops.
• Output current to lockup solenoid can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV LU DIR - 31609)
information
• Method of reproducing failure code: Turn starting switch ON.
22 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 23
SEN01114-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01114-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 25
SEN01114-00 40 Troubleshooting
26 HM400-2
40 Troubleshooting SEN01114-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 27
SEN01114-00 40 Troubleshooting
28 HM400-2
40 Troubleshooting SEN01114-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 29
SEN01114-00 40 Troubleshooting
30 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 31
SEN01114-00 40 Troubleshooting
32 HM400-2
40 Troubleshooting SEN01114-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 33
SEN01114-00 40 Troubleshooting
34 HM400-2
40 Troubleshooting SEN01114-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 35
SEN01114-00 40 Troubleshooting
36 HM400-2
40 Troubleshooting SEN01114-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 37
SEN01114-00 40 Troubleshooting
38 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 39
SEN01114-00 40 Troubleshooting
40 HM400-2
40 Troubleshooting SEN01114-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 41
SEN01114-00 40 Troubleshooting
42 HM400-2
40 Troubleshooting SEN01114-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 43
SEN01114-00 40 Troubleshooting
Failure code [DXH4KY] Hot short in output circuit of 1st clutch ECMV
solenoid valve 1
Action code Failure code Hot short in output circuit of 1st clutch ECMV solenoid valve
Trouble
E03 DXH4KY (Transmission controller system)
Contents of
• When output to 1st clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Action of • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2".
controller • Turns lockup system OFF.
Problem that
appears on • If gearshift lever is set in "N", machine cannot restart until it stops.
machine
• Output current to 1st clutch ECMV solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV 1 DIR - 31602)
information
• Method of reproducing failure code: Turn starting switch ON.
44 HM400-2
40 Troubleshooting SEN01114-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 45
SEN01114-00 40 Troubleshooting
46 HM400-2
40 Troubleshooting SEN01114-00
HM400-2 47
SEN01114-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
48 HM400-2
SEN01115-00
HM400-2
40 Troubleshooting 1
Troubleshooting by failure code, Part 8
Troubleshooting by failure code, Part 8 .......................................................................................................... 2
Failure code [DXH5KA] Disconnection in output circuit of 2nd clutch solenoid ................................... 2
Failure code [DXH5KB] Ground fault in output circuit of 2nd clutch ECMV solenoid valve ................. 4
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV solenoid valve....................... 6
Failure code [DXH6KA] Disconnection in output circuit of 3rd clutch solenoid .................................. 10
Failure code [DXH6KB] Ground fault in output circuit of 3rd clutch ECMV solenoid valve ................ 12
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV solenoid valve ..................... 14
Failure code [DXH7KA] Disconnection in output circuit of reverse clutch solenoid ........................... 18
Failure code [DXH7KB] Ground fault in output circuit of reverse clutch ECMV solenoid valve ......... 20
Failure code [DXH7KY] Hot short in output circuit of reverse clutch ECMV solenoid valve............... 22
HM400-2 1
SEN01115-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01115-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 3
SEN01115-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01115-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 5
SEN01115-00 40 Troubleshooting
Failure code [DXH5KY] Hot short in output circuit of 2nd clutch ECMV
solenoid valve 1
Action code Failure code Hot short in output circuit of 2nd clutch ECMV solenoid valve
Trouble
E03 DXH5KY (Transmission controller system)
Contents of
• When output to 2nd clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Action of • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2".
controller • Turns lockup system OFF.
Problem that
appears on • If gearshift lever is set in "N", machine cannot restart until it stops.
machine
• Output current to 2nd clutch ECMV solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV 2 DIR - 31603)
information
• Method of reproducing failure code: Turn starting switch ON.
6 HM400-2
40 Troubleshooting SEN01115-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 7
SEN01115-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01115-00
HM400-2 9
SEN01115-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01115-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 11
SEN01115-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01115-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 13
SEN01115-00 40 Troubleshooting
Failure code [DXH6KY] Hot short in output circuit of 3rd clutch ECMV
solenoid valve 1
Action code Failure code Hot short in output circuit of 3rd clutch ECMV solenoid valve
Trouble
E03 DXH6KY (Transmission controller system)
Contents of
• When output to 3rd clutch ECMV solenoid valve is turned OFF, some current flows.
trouble
Action of • Shifts up and keeps gear speed according to gear speed before trouble and "Table 2".
controller • Turns lockup system OFF.
Problem that
appears on • If gearshift lever is set in "N", machine cannot restart until it stops.
machine
• Output current to 3rd clutch ECMV solenoid valve can be checked with monitoring function.
Related
(Monitoring code: TRANSMISSION - ECMV 3 DIR - 31604)
information
• Method of reproducing failure code: Turn starting switch ON.
14 HM400-2
40 Troubleshooting SEN01115-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 15
SEN01115-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01115-00
HM400-2 17
SEN01115-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01115-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 19
SEN01115-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01115-00
Table 1
Remedy against trouble
Gear speed before
Clutch having trouble Action of controller ON/OFF state of
trouble
(Selected clutch and gear speed) lockup clutch
3rd 3rd OFF NEUTRAL OFF
F6
Hi Hi OFF NEUTRAL OFF
3rd 3rd OFF NEUTRAL OFF
F5
Lo Lo 3H F6 OFF
2nd 2nd 3L F5 OFF
F4
Hi Hi 3L F5 OFF
2nd 2nd 3L F5 OFF
F3
Lo Lo 2H F4 OFF
1st 1st 2L F3 OFF
F2
Hi Hi 2L F3 OFF
1st 1st 2L F3 OFF
F1
Lo Lo 1H F2 OFF
3rd 3rd OFF NEUTRAL OFF
R3
Reverse Reverse OFF NEUTRAL OFF
2nd 2nd 3R R3 OFF
R2
Reverse Reverse OFF NEUTRAL OFF
1st 1st 2R R2 OFF
R1
Reverse Reverse OFF NEUTRAL OFF
HM400-2 21
SEN01115-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01115-00
Table 2
Remedy against trouble
Gear speed
Clutch having trouble Action of controller ON/OFF state of
before trouble
(Selected clutch and gear speed) lockup clutch
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F6
Hi Reverse OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
F5
Lo Reverse OFF NEUTRAL OFF
Hi 3H F6 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F4
Hi Reverse OFF NEUTRAL OFF
Lo 3L F5 OFF
3rd 3L F5 OFF
2nd 1st OFF NEUTRAL OFF
F3
Lo Reverse OFF NEUTRAL OFF
Hi 2H F4 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F2
Hi Reverse OFF NEUTRAL OFF
Lo 2L F3 OFF
3rd 3L F5 OFF
1st 2nd 2L F3 OFF
F1
Lo Reverse OFF NEUTRAL OFF
Hi 1H F2 OFF
2nd OFF NEUTRAL OFF
3rd 1st OFF NEUTRAL OFF
R3
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
2nd 1st OFF NEUTRAL OFF
R2
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
3rd 3R R3 OFF
1st 2nd 2R R2 OFF
R1
Reverse Hi OFF NEUTRAL OFF
Lo OFF NEUTRAL OFF
N ANY NONE No reaction —
HM400-2 23
SEN01115-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01115-00
HM400-2 25
SEN01115-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
26 HM400-2
SEN01116-00
HM400-2
40 Troubleshooting 1
Troubleshooting for electrical system
(E-mode)
Troubleshooting for electrical system (E-mode).............................................................................................. 3
Before troubleshooting for electrical system ........................................................................................ 3
Information in troubleshooting table ..................................................................................................... 9
E-1 Engine does not start (Starting motor does not turn) .................................................................. 10
E-2 Auto preheater does not operate................................................................................................ 14
E-3 When starting switch is turned ON, machine monitor displays nothing ...................................... 18
E-4 When starting switch is turned OFF, machine monitor cannot be operated ............................... 20
E-5 Alarm buzzer does not sound..................................................................................................... 22
E-6 Machine monitor does not normally display gauges,
caution lamps, and character display section ............................................................................. 24
E-7 Display of character display section cannot be changed............................................................ 25
E-8 Power mode selection function does not operate normally ........................................................ 28
E-9 AISS function does not operate normally ................................................................................... 30
HM400-2 1
SEN01116-00 40 Troubleshooting
E-10 Right and left differential lock function does not operate
normally (Differential lock-up specification).............................................................................. 32
E-11 Interaxle differential lock-up function does not operate normally .............................................. 36
E-12 Display of seat belt caution lamp is abnormal .......................................................................... 38
E-13 Turn signal lamps and pilot lamps do not operate normally...................................................... 40
E-14 Night lighting is abnormal ......................................................................................................... 45
E-15 Backup lamp and backup buzzer operate abnormally.............................................................. 51
E-16 Emergency steering system does not operate ......................................................................... 55
2 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 3
SEN01116-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 5
SEN01116-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 7
SEN01116-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01116-00
<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected defectively or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24
2 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are refer-
<Precautions for troubleshooting>
state ence numbers, which do
(1) Method of indicating connector No. and handling of T-
not indicate priority)
adapter
Insert or connect T-adapter as explained below for trouble-
shooting, unless otherwise specified.
3 • If connector No. has no marks of "male" and "female",
disconnect connector and insert T-adapters in both male
side and female side.
• If connector No. has marks of "male" and "female", dis-
connect connector and connect T-adapter to only male
side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as
explained below for troubleshooting, unless otherwise
specified.
4 • Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or harness entered
on rear side.
HM400-2 9
SEN01116-00 40 Troubleshooting
E-1 Engine does not start (Starting motor does not turn) 1
Trouble • Engine does not start (Starting motor does not turn).
Related
• Engine starting circuit is equipped with start lock mechanism of gearshift lever.
information
10 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 11
SEN01116-00 40 Troubleshooting
12 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 13
SEN01116-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 15
SEN01116-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 17
SEN01116-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 19
SEN01116-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 21
SEN01116-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 23
SEN01116-00 40 Troubleshooting
E-6 Machine monitor does not normally display gauges, caution lamps,
and character display section 1
Trouble (1) Display of gauges is different from machine condition.
Related
information
24 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 25
SEN01116-00 40 Troubleshooting
(2) When machine monitor mode selector switch 2 is operated, display of character display section
Trouble
does not change normally.
Related
information
26 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 27
SEN01116-00 40 Troubleshooting
28 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 29
SEN01116-00 40 Troubleshooting
30 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 31
SEN01116-00 40 Troubleshooting
E-10 Right and left differential lock function does not operate normally
(Differential lock-up specification) 1
(1) When right and left differential lock-up switch is operated, right and left differential lock-up function
Trouble does not operate normally or right and left differential lock-up pilot lamp is not turned ON or OFF
normally.
Related
information
32 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 33
SEN01116-00 40 Troubleshooting
(2) When right and left differential lock-up pedal is operated, right and left differential lock-up function
Trouble does not operate normally or right and left differential lock-up pilot lamp is not turned ON or OFF
normally.
Related
information
34 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 35
SEN01116-00 40 Troubleshooting
36 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 37
SEN01116-00 40 Troubleshooting
38 HM400-2
40 Troubleshooting SEN01116-00
Trouble (2) While seat belt is not fastened, seat belt caution lamp does not light up.
Related
information
HM400-2 39
SEN01116-00 40 Troubleshooting
E-13 Turn signal lamps and pilot lamps do not operate normally 1
Trouble (1) When turn signal lever and hazard lamp switch are operated, no turn signal lamps blink.
Related • Turn signal line is branched at switch and relay toward right, left, front, and rear. If only 1 lamp is
information defective, bulb may be broken or wiring harness on signal side or ground side may be defective.
Trouble (2) When turn signal lever and hazard lamp switch are operated, turn signal lamps do blink but light up.
Related
information
40 HM400-2
40 Troubleshooting SEN01116-00
(3) When turn signal lever and hazard lamp switch are operated, turn signal lamps on either of both
Trouble
sides do not blink (They blink normally when hazard switch is turned ON, however).
Related • Turn signal line is branched at switch and relay toward right, left, front, and rear. If only 1 lamp is
information defective, bulb may be broken or wiring harness on signal side or ground side may be defective.
HM400-2 41
SEN01116-00 40 Troubleshooting
(4) When hazard lamp switch is turned ON, no turn signal lamps blink (When turn signal lever is oper-
Trouble
ated, however, turn signal lamps blink normally).
Related
information
42 HM400-2
40 Troubleshooting SEN01116-00
(5) When hazard lamp switch is turned OFF, turn signal lamps blink (They blink normally when turn
Trouble
signal lever is operated, however).
Related
information
Trouble (6) Turn signal pilot lamps do not blink normally (Turn signal lamps blink normally, however).
Related
information
HM400-2 43
SEN01116-00 40 Troubleshooting
Circuit diagram related to turn signal lever, turn signal lamps, and turn signal pilot lamps
44 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 45
SEN01116-00 40 Troubleshooting
Trouble (2) When lamp switch is set to 1st position, small lamps and night lamps do not light up.
• Lamp and night lighting line is branched at switch and relay toward right, left, front, and rear. If only
Related
1 lamp is defective, bulb may be broken or wiring harness on signal side or ground side may be
information
defective.
Trouble (3) When lamp switch is turned OFF, small lamps and night lamps light up.
Related
information
46 HM400-2
40 Troubleshooting SEN01116-00
Trouble (4) When brightness control switch is operated, brightness of night lighting does not change.
• Lamp and night lighting line is branched at switch and relay toward right, left, front, and rear. If only
Related
1 lamp is defective, bulb may be broken or wiring harness on signal side or ground side may be
information
defective.
Trouble (5) When lamp switch is set to 2nd position, head lamps do not light up.
Related
information
HM400-2 47
SEN01116-00 40 Troubleshooting
Trouble (6) High beam of headlamp does not light up (Low beam lights up, however).
• Lamp and night lighting line is branched at switch and relay toward right, left, front, and rear. If only
Related
1 lamp is defective, bulb may be broken or wiring harness on signal side or ground side may be
information
defective.
48 HM400-2
40 Troubleshooting SEN01116-00
Trouble (7) Low beam of headlamp does not light up (High beam lights up, however).
• Lamp and night lighting line is branched at switch and relay toward right, left, front, and rear. If only
Related
1 lamp is defective, bulb may be broken or wiring harness on signal side or ground side may be
information
defective.
(8) When high beam of headlamp is turned ON, pilot lamp on machine monitor does not light up (High
Trouble
beam lights up, however).
Related
information
HM400-2 49
SEN01116-00 40 Troubleshooting
50 HM400-2
40 Troubleshooting SEN01116-00
(2) When gearshift lever is set to R1, backup lamp and backup buzzer do not operate (They operate
Trouble
normally at R2, however).
Related
information
HM400-2 51
SEN01116-00 40 Troubleshooting
(3) When gearshift lever is set to R2, backup lamp and backup buzzer do not operate (They operate
Trouble
normally at R1, however).
Related
information
(4) Right backup lamp and backup buzzer do not operate (Left backup lamp operates normally, how-
Trouble
ever).
• Right backup lamp and backup buzzer use common signal circuit. If only either of them does not
Related
operate, backup lamp bulb may be broken, backup buzzer may be defective, or wiring harness of
information
signal circuit or ground circuit may be defective.
52 HM400-2
40 Troubleshooting SEN01116-00
(5) Left backup lamp does not operate (Right backup lamp and backup buzzer operate normally, how-
Trouble
ever).
Related
information
Trouble (6) While gearshift lever is not at R1 or R2, backup lamp and backup buzzer operate.
Related
information
HM400-2 53
SEN01116-00 40 Troubleshooting
54 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 55
SEN01116-00 40 Troubleshooting
56 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 57
SEN01116-00 40 Troubleshooting
58 HM400-2
40 Troubleshooting SEN01116-00
HM400-2 59
SEN01116-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
60 HM400-2
SEN01117-00
HM400-2
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Information in troubleshooting table...................................................................................................... 3
H-1 Machine does not start.................................................................................................................. 4
H-2 Travel is not smooth (Machine hunts) ........................................................................................... 6
H-3 Lockup is not reset........................................................................................................................ 6
H-4 Start shock and gear shift shock are abnormally large ................................................................. 7
H-5 Gear is not shifted up .................................................................................................................... 8
H-6 Travel speed or power is low ...................................................................................................... 10
H-7 Start and gearshift time lag is large ............................................................................................ 14
H-8 Torque converter oil temperature is high .................................................................................... 16
H-9 Torque converter oil temperature is low...................................................................................... 17
H-10 Front brake does not work fully ................................................................................................. 18
H-11 Center brake does not work fully .............................................................................................. 19
H-12 Rear brake does not work fully ................................................................................................. 20
HM400-2 1
SEN01117-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01117-00
Possible causes 2
and standard Possible causes of trouble
<Contents of description>
value in normal (Given numbers are refer-
• Standard value in normal state to judge possible causes
state ence numbers, which do
• Remarks on judgment
not indicate priority)
3
HM400-2 3
SEN01117-00 40 Troubleshooting
4 HM400-2
40 Troubleshooting SEN01117-00
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM400-2 5
SEN01117-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01117-00
H-4 Start shock and gear shift shock are abnormally large 1
Trouble • Start shock and gear shift shock are abnormally large
Related • If any failure code of mechanical system is displayed or recorded, carry out troubleshooting for it
information first.
HM400-2 7
SEN01117-00 40 Troubleshooting
8 HM400-2
40 Troubleshooting SEN01117-00
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM400-2 9
SEN01117-00 40 Troubleshooting
10 HM400-2
40 Troubleshooting SEN01117-00
Trouble (2) Travel speed or power is low at during torque converter travel.
• Check that transmission oil level is normal.
• If any failure code of mechanical system is displayed or recorded, carry out troubleshooting for it
Related
first.
information
• Check that oil is not leaking from power train piping.
• Check that parking brake is released securely and retarder is not dragging.
HM400-2 11
SEN01117-00 40 Troubleshooting
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
12 HM400-2
40 Troubleshooting SEN01117-00
HM400-2 13
SEN01117-00 40 Troubleshooting
14 HM400-2
40 Troubleshooting SEN01117-00
Clutch used
Lo Hi 1st 2nd 3rd R
R1 q q
R2 q q
N
Gear speed
F1 q q
F2 q q
F3 q q
F4 q q
F5 q q
F6 q q
HM400-2 15
SEN01117-00 40 Troubleshooting
16 HM400-2
40 Troubleshooting SEN01117-00
HM400-2 17
SEN01117-00 40 Troubleshooting
18 HM400-2
40 Troubleshooting SEN01117-00
HM400-2 19
SEN01117-00 40 Troubleshooting
20 HM400-2
40 Troubleshooting SEN01117-00
HM400-2 21
SEN01117-00 40 Troubleshooting
22 HM400-2
40 Troubleshooting SEN01117-00
HM400-2 23
SEN01117-00 40 Troubleshooting
24 HM400-2
40 Troubleshooting SEN01117-00
HM400-2 25
SEN01117-00 40 Troubleshooting
2 Defective dump cylinder Raise dump body and disconnect hydraulic hose on dump cylinder
head side and relieve dump cylinder at raise stroke end. If oil flows
out of dump cylinder at this time, piston ring of dump cylinder is
defective.
26 HM400-2
40 Troubleshooting SEN01117-00
HM400-2 27
SEN01117-00 40 Troubleshooting
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
28 HM400-2
SEN01118-00
HM400-2
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 4
Method of using troubleshooting chart ................................................................................................. 4
S-1 Starting performance of engine is poor.......................................................................................... 8
S-2 Engine does not start................................................................................................................... 10
S-3 Engine does not pick up smoothly............................................................................................... 14
S-4 Engine stops during operation ..................................................................................................... 15
S-5 Engine does not rotate smoothly ................................................................................................. 16
S-6 Engine lack output (or lacks power) ............................................................................................ 17
S-7 Exhaust gas is black (incomplete combustion)............................................................................ 18
S-8 Oil consumption is excessive (or exhaust gas is blue) ................................................................ 20
S-9 Oil becomes dirty quickly............................................................................................................. 21
S-10 Fuel consumption is excessive.................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23
S-12 Oil pressure drops ..................................................................................................................... 24
S-13 Oil level rises (Entry of coolant or fuel)...................................................................................... 26
S-14 Coolant temperature becomes too high (Overheating) ............................................................. 28
HM400-2 1
SEN01118-00 40 Troubleshooting
2 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 3
SEN01118-00 40 Troubleshooting
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the "causes", apply the items marked with w before those marked with Q.
When narrowing the "causes", do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 5
SEN01118-00 40 Troubleshooting
6 HM400-2
40 Troubleshooting SEN01118-00
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] section.
The method of pinpointing the [Causes] from the causal relationship and approaching the [troubleshooting]
is explained according to Step 1 - Step 3 shown below.
HM400-2 7
SEN01118-00 40 Troubleshooting
Defective injector
turns at maximum. This phenomenon does not indi-
cate a trouble, however
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 9
SEN01118-00 40 Troubleshooting
Degree of use of
Operated for long period E E E
machine
When starting switch is Horn does not sound Q Q w
turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
When starting switch is turned ON, no operating sound comes out from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Replace
Replace
Replace
Replace
Correct
Remedy
—
10 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 11
SEN01118-00 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
12 HM400-2
40 Troubleshooting SEN01118-00
When air bleeding plug of fuel filter is removed, fuel does not
While engine is rotated flow out Q w w
with starting motor,
When spill hose from injector is disconnected, little fuel spills w
Immediately after engine is started, temperature of exhaust manifold of a cylinder is low w
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
HM400-2 13
SEN01118-00 40 Troubleshooting
When engine is rotated, abnormal sound comes out from around cylinder head w
When engine is rotated, interference sound comes out from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
Engine hunts (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
14 HM400-2
40 Troubleshooting SEN01118-00
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
HM400-2 15
SEN01118-00 40 Troubleshooting
There are rust and water in fuel drained from fuel tank Q Q
Fuel is leaking from fuel piping w
Priming pump is too light or too heavy to operate w Q Q
Carry out troubleshooting according to "EGR Valve Servo Error (*1)" indicated by code q
Carry out troubleshooting according to "Bypass Valve Servo Error (*2)" indicated by
code q
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
Add
16 HM400-2
40 Troubleshooting SEN01118-00
turbocharger
When engine is rotated, abnormal sound comes out from around cylinder head w
High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load
is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
Engine hunts (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
HM400-2 17
SEN01118-00 40 Troubleshooting
When engine is rotated, abnormal sound comes out from around cylinder
head w
Torque converter stall speed or pump relief speed is high (Fuel is injected
excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
Blow-by gas is excessive w
When spill hose from injector is disconnected, abnormally much fuel spills w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 19
SEN01118-00 40 Troubleshooting
Turbocharger
Worn or damaged valve (stem, guide, or seal)
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 HM400-2
40 Troubleshooting SEN01118-00
Exhaust gas is
Black w
Comes out excessively Q Q w Q
Blow-by gas
Does not come out at all w
See S-7
Check breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
HM400-2 21
SEN01118-00 40 Troubleshooting
Carry out troubleshooting according to "Rail Press (Very) Low Error (*1)" indicated by code q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
When spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to "Coolant Temp Sens High (Low) Error (*2)" indicated by
code q
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
22 HM400-2
40 Troubleshooting SEN01118-00
When hydraulic oil or power train oil is drained, water flows out w
Remedy
—
HM400-2 23
SEN01118-00 40 Troubleshooting
When oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Remedy
—
Add
24 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 25
SEN01118-00 40 Troubleshooting
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out
q
(*1).
Compression pressure is low q
Remove and inspect head cover directly q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
26 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 27
SEN01118-00 40 Troubleshooting
Malfunction of thermostat
Occurred suddenly Q Q w Q
Overheating
Has continued at low level Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates low (if monitor is installed) Q w
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
Fan pulley has play w
Milky oil is floating on coolant w
There are many bubbles in radiator and coolant spurts back w
When light applied to radiator core, no light passes through w
Check items
Dirt and mud are accumulated in radiator shroud and undercover on applicable
machine side w w
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
28 HM400-2
40 Troubleshooting SEN01118-00
Gradually increased Q Q
Abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is used Q
Oil must be added more frequently w
There are metal particles in oil drained from oil filter w w
Air leaks between turbocharger and cylinder head w
When engine is rotated, interference sound comes out from around turbocharger w
When engine is rotated, abnormal sound comes out from around EGR gas
w
piping
When engine is rotated, abnormal sound comes out from around cylinder head w w
When engine is rotated, beat noise comes out from around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
HM400-2 29
SEN01118-00 40 Troubleshooting
Replace
Replace
Replace
Adjust
Adjust
Remedy
30 HM400-2
40 Troubleshooting SEN01118-00
HM400-2 31
SEN01442-00
HM400-2
HM400-2 1
SEN01442-00 50 Disassembly and assembly
1) Necessity of work.
t : Special tools that cannot be substi- a: This mark gives guidance or precautions when
tuted and should always be used doing the procedure.
(installed). [*1] : This mark shows that there are instructions or
q : Special tools that will be useful if avail- precautions for installing parts.
able and are substitutable with com- 6 : This mark shows the amount of oil or coolant
mercially available tools. to be drained.
2) Distinction of new and existing special 4 : Weight of part or component
tools
N: Tools newly developed for this
model. They respectively have a Installation
new part number. q Except where otherwise instructed, installation
R: Tools with upgraded part numbers. of parts is done in the reverse order of removal.
They are remodeled from already q Instructions and precautions for installing parts
available tools for other models. are shown with [*1] mark in the "Removal" sec-
Blank: Tools already available for other tion, identifying which step the instructions are
models. They can be used without intended for.
any modification. q Marks shown in the "Installation" section stand
3) Circle mark Q in sketch column: for the following.
q The sketch of the special tool is pre- k : Precautions related to safety in execution
sented in the section of "Sketches of of work.
special tools". a: This mark gives guidance or precautions when
q Part No. of special tools starting with doing the procedure.
2 : Type of coating material
* *** ****
79 T- - :
means that they can not be supplied 3 : Tightening torque
5
from Komatsu in Japan (i.e. locally : Quantity of oil or coolant to be added
made parts ).
Sketches of special tools
a General tools that are necessary for
q Various special tools are illustrated for the con-
removal or installation are described as
venience of local manufacture.
[1], [2]•••etc. and their part names, part
numbers and quantities are not described.
2 HM400-2
50 Disassembly and assembly SEN01442-00
HM400-2 3
SEN01442-00 50 Disassembly and assembly
List of adhesives
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cushions, and
LT-1A 790-129-9030 150 g Tube
cork plugs from coming out.
• Used for plastic (except polyethylene, polypropylene,
20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, metal,
LT-1B 790-129-9050
(2 pcs.) container and non-metal parts which require immediate and
strong adhesion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of 1 kg
LT-3 Can • Used to stick and seal metal, glass, and plastics.
adhesive and Hardener:
hardener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH
790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
705
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics, and
woods.
• Quick-setting adhesive.
Aron-alpha Polyethylene • Quick-setting type.
790-129-9130 2g
201 container (max. strength is obtained after 30 minutes)
• Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistance to heat and chemicals.
79A-129-9110 50 cc
648-50 container • Used for fitted portions used at high temperatures.
• Used to stick or seal gaskets and packings of power
LG-1 790-129-9010 200 g Tube
train case, etc.
• Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nipples of
hydraulic piping.
• Features: Silicon-based heat and cold-resistant seal-
Gasket sealant
ant.
LG-6 790-129-9020 200 g Tube
• Used to seal flange surfaces and threaded portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resistant,
ThreeBond
419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B
• Used to seal transfer case, etc.
4 HM400-2
50 Disassembly and assembly SEN01442-00
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
molybdenum disulfide
ing part.
SYGA-16CNM 16 kg Can
LM-G(G2-M)
SYG2-400T-A
Hyper white
SYG2-16CNT
grease • Higher anti seizure and heat resistance than
SYG0-400T-A 400 g Bellows type
G2-T GO-T(*) grease with molybdenum disulphide
(*) 16 kg Can
*: For cold • Body dirt is not distinctive due to white color.
SYG0-16CNT
region
(*)
Biological
SYG2-400B
grease G2-B
SYGA-16CNB
G2-BT(*) • To be shortly dissolved by a bacteria in nature
SYG2-400BT 400 g Bellows type
*: For heat so that the influence to microorganism and ani-
(*) 16 kg Can
resistance mals and plants is suppressed to the minimum.
SYGA-16CNBT
and heavy
(*)
load
Sunstar
• To be used as primer for cab side.
primer for Glass
20 ml (Term of validity: 4 months after manufac-
painting plane container
turing)
580 super
417-926-3910
Sunstar
• To be used as primer for glass side.
primer for Glass
20 ml (Term of validity: 4 months after manufac-
glass 580 container
For adhesion of cab glass
turing)
super
Sunstar • To be used as primer for painting plane of
primer for Glass cab side.
Primer
22M-54-27230 20 ml
painting plane container (Term of validity: 4 months after manufac-
435-95 turing)
• To be used as primer for black ceramic
Sunstar
coated plane of glass side and polycarbon-
primer for
22M-54-27240 150 ml Steel can ate hard coat plane.
glass
(Term of validity: 4 months after manufac-
435-41
turing)
Sunstar • To be used as primer for sash (Alumite
primer for Glass surface treatment)
22M-54-27250 20 ml
sash container (Term of validity: 4 months after manufac-
GP-402 turing)
HM400-2 5
SEN01442-00 50 Disassembly and assembly
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
• "S" and "W" are used as glass adhesive
Sunstar pen- compound in high temperature (April -
guin seal 580 Polyethylene October) and in low temperature (October
417-926-3910 320 ml
Adhesive compound
6 HM400-2
50 Disassembly and assembly SEN01442-00
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
1 795-630-5500 Standard puller t 1
Removal and installa- Removal of fuel supply
2 01010-81090 Bolt t 2
tion of fuel supply pump pump
3 01643-31032 Washer t 2
4 792-220-1110 Centering tool t 2 Centering of engine assem-
Removal and installa-
bly and transmission
tion of engine assembly A 5 01050-61225 Bolt t 8 assembly
Removal and installa-
Adjustment of clearance in
tion of fuel injector and 6 795-125-1210 Thickness gauge t 1
crosshead
cylinder head
Removal and installa- Angle tightening of cylinder
7 790-331-1110 Angle tightening wrench t 1
tion of cylinder head head bolt
790-201-2210 Plate t 1
790-201-2740 Spacer t 1
791-600-1120 Bolt t 1
790-101-2540 Washer t 1 Press fitting of shaft
1
01580-01613 Nut t 1 bearing
HM400-2 7
SEN01442-00 50 Disassembly and assembly
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
Removal, installation of
4 790-102-1871 Nut wrench t 1
PTO gear bearing set nut
Press fitting of pump
5 790-201-2730 Spacer t 1
bearing
Press fitting of stator shaft
6 793T-623-1170 Push tool t 1 N Q
bearing
Disassembly, assembly 7 792T-413-1120 Push tool t 1 N Q Press fitting of gear bearing
C
of torque converter Press fitting of coupling
8 792T-413-1130 Push tool t 1 N Q
cover
790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
9 Press fitting of cage oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
790-201-2750 Spacer t 1 Press fitting of shaft
1
790-201-2850 Spacer t 1 bearing
790-101-5401 Push tool kit t 1
790-101-5461 • Plate 1
2 Press fitting of cage oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Press fitting of coupling
3 792T-415-1310 Push tool t 1 N Q
cover
Check of operation of
4 799-301-1500 Oil leak tester kit t 1
clutch piston
792T-415-1320 Block t 2 N Q Disassembly of 2nd and
Disassembly, assembly 5
D 01010-81050 Bolt t 2 3rd clutch assembly
of transmission
790-101-2501 Push puller t 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
6
790-101-2570 • Plate 4 clutch bearing inner case
790-101-2630 • Leg 2
790-101-2660 • Adapter 2
791-112-1180 • Nut 1
790-201-1320 • Spacer t 1
790-201-2850 Spacer t 1 Press fitting of bevel pinion
1 790-201-2740 Spacer t 1 bearing (For R/F
790-201-2750 Spacer t 1 differential)
Disassembly, assembly 790-101-5401 Push tool kit t 1
H
of axle
790-101-5481 • Plate 1 Press fitting of oil seal to
2
790-101-5421 • Grip 1 cage (For front differential)
01010-51240 • Bolt 1
8 HM400-2
50 Disassembly and assembly SEN01442-00
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
For rear
790-201-2770 Spacer t 1
differential
Press fitting
3 For front of output
differential, shaft seal
792T-423-1130 Push tool t 1 N Q
R/F
differential
790-201-2740 Spacer t 1 Press fitting of shaft
4 792T-423-1110 Push tool t 1 N Q bearing (For front
792T-423-1120 Push tool t 1 N Q differential, R/F differential)
Press fitting of cage input
5 792T-423-1130 Push tool t 1 N Q
seal
792-103-0901 Wrench t 1
Adjustment of preload on
6 792-222-1110 Adapter t 2
bearing
795-525-1000 Micrometer t 1
796-751-1500 Wrench assembly t 1 Measurement of turning
7
795-630-1803 Torque wrench t 1 torque of side gear
Press fitting of pin (for
8 792T-422-1250 Push tool t 1 N Q
differential assembly)
Disassembly, assembly 790-501-5000 Unit repair stand t 1 AC100V
H Disassembly,
of axle 790-501-5200 Unit repair stand t 1 AC110, 220V assembly of
9
790-901-2110 Bracket t 1 differential
assembly
793-310-2141 Plate t 1 R Q
792T-422-1260 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-101-5401 Push tool kit t 1 Press fitting of differential
10
lock gauge input seal
790-101-5471 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
792T-423-1140 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
790-101-5401 Push tool kit t 1 Press fitting of differential
11
(R/F) gauge input seal
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
792T-422-1210 Fixture t 3 N Q For rear
Removal,
792T-427-1110 Fixture t 3 N Q For front installation of
1
01010-61435 Bolt t 3 brake
Disassembly, assembly assembly
J 01010-62440 Bolt t 3
of final drive and brake
792T-422-1220 Plate t 1 N Q
2 790-101-5421 Grip t 1 Press fitting of oil seal
01010-51240 Bolt t 1
HM400-2 9
SEN01442-00 50 Disassembly and assembly
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
Press fitting of bearing to
3 792T-422-1230 Push tool t 1 N Q
hub
Press fitting of bearing to
4 792T-422-1240 Push tool t 1 N Q
tube
Disassembly, assembly 792-520-2110 Installer t 1
J For large
of final drive and brake
792-530-1600 Push tool t 1 diameter Fitting of
5
For small floating seal
790-434-1620 Installer t 1
diameter
6 793-520-1805 Brake tester t 1 Check for brake oil leakage
Disassembly, assembly 792-620-1001 Tire remover t 1 Removal of tire from wheel
R 1
of wheel 790-101-1102 Hydraulic pump t 1 assembly
792T-446-1110 Push tool t 1 N Q
Press fitting of bearing to
1 792T-446-1120 Push tool t 1 N Q
hitch frame
792T-446-1150 Push tool t 1 N Q
790-101-5401 Push tool kit t 1
790-101-5461 • Plate 1 Press fitting of oil seal to
Disassembly, assembly 2
790-101-5421 • Grip 1 frame
of hitch frame
01010-51240 • Bolt 1
792T-446-1130 Plate t 1 N Q
792T-446-1140 Plate t 1 N Q Press fitting of oil seal to
3
790-101-5421 Grip t 1 cage and frame
01010-51240 Bolt t 1
Q 790-201-1702 Push tool kit t 1
790-201-1881 • Push tool 1
4 Press fitting of roll bushing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1500 Push tool kit t 1
Disassembly, assembly 790-201-1690 • Plate 1
of suspension 5 Press fitting of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Suspension tool
792-610-1000 t 1
assembly
Filling with oil and nitrogen
6
792-610-1100 • Pump assembly 1 gas
792-610-1200 • Charging tool assembly 1
Disassembly, assembly 790-452-1100 Seal installer set t 1 Disassembly, assembly of
T 1
of steering valve 790-452-1200 Pilot ring tool t 1 steering valve
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of
1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
10 HM400-2
50 Disassembly and assembly SEN01442-00
New/remodel
Necessity
Sym-
Component Part No. Part Name Nature of work, remarks
Sketch
bol
Q’ty
790-720-1000 Expander t 1
796-720-1670 Ring t 1 Steering, No.
4 07281-01279 Clamp t 1 2 hoist Installation
796-720-1680 Ring t 1 For No. 1 of piston ring
07281-01289 Clamp t 1 hoist cylinder
790-201-1702 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
For steering Press fitting
5 790-201-1811 • Push tool 1 of roll
cylinder
bushing
Disassembly, assembly For No. 1
U 790-201-1881 • Push tool 1
of hydraulic cylinder hoist cylinder
For No. 2
790-201-1841 • Push tool 1
hoist cylinder
790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
For steering Press fitting
6 790-201-1620 • Plate 1
cylinder of dust seal
For No. 1
790-201-1690 • Plate 1
hoist cylinder
For No. 2
790-201-1650 • Plate 1
hoist cylinder
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100V) t 1
Air connditioner Filling with air conditioer
X 1 799-703-1111 Vacuum pump (220V) t 1
assembly refrigerant (gas)
799-703-1121 Vacuum pump (240V) t 1
799-703-1401 Gas leak detecter t 1
Charging accumulator with
Accumulator assembly Y 1 792-610-1700 Gas charge tool
gas
HM400-2 11
SEN01442-00 50 Disassembly and assembly
C1 Plate
C6 Push tool
12 HM400-2
50 Disassembly and assembly SEN01442-00
C7 Push tool
C8 Push tool
HM400-2 13
SEN01442-00 50 Disassembly and assembly
D3 Push tool
D5 Block
14 HM400-2
50 Disassembly and assembly SEN01442-00
H4 Push tool
HM400-2 15
SEN01442-00 50 Disassembly and assembly
H4 Push tool
H8 Push tool
16 HM400-2
50 Disassembly and assembly SEN01442-00
H9 Plate
H9 Arm
HM400-2 17
SEN01442-00 50 Disassembly and assembly
18 HM400-2
50 Disassembly and assembly SEN01442-00
J1 Fixture
J1 Fixture
HM400-2 19
SEN01442-00 50 Disassembly and assembly
J2 Push tool
J3 Push tool
20 HM400-2
50 Disassembly and assembly SEN01442-00
J4 Push tool
Q1 Push tool
HM400-2 21
SEN01442-00 50 Disassembly and assembly
Q1 Push tool
Q1 Push tool
22 HM400-2
50 Disassembly and assembly SEN01442-00
Q3 Push tool
Q3 Push tool
HM400-2 23
SEN01443-00
HM400-2
HM400-2 1
SEN01443-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 795-630-5500 Standard puller t 1
A 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2
4. Remove mounting nut (5). [*1]
Removal a Take care not to drop the nut in the gear
case.
1. Tilt up engine hood (1).
2 HM400-2
50 Disassembly and assembly SEN01443-00
7. Disconnect connector (CN-ACRD) (8) of the 13. Remove fuel filter and head assembly (16).
receiver tank.
14. Remove oil level gauge (17), oil filler tube (18),
8. Remove the band and move receiver tank (9) and blow-by tube (19).
outward and fix it with wires.
HM400-2 3
SEN01443-00 50 Disassembly and assembly
[*3]
3 Sleeve nut (Supply pump side):
39.2 – 49 Nm {4 – 5 kgm}
3 Sleeve nut (Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
[*4]
3 Plug: 17.7 – 22.6 Nm {1.8 – 2.3 kgm}
4 HM400-2
50 Disassembly and assembly SEN01443-00
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
4 792-220-1110 Centering tool t 2
A
5 01050-61225 Bolt t 8
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
HM400-2 5
SEN01443-00 50 Disassembly and assembly
4) Remove hose (10). 7. Remove the right aftercooler hose and pipe
5) Remove hose clamp (11). (16).
6 HM400-2
50 Disassembly and assembly SEN01443-00
3) Remove bracket (19) and V-belt (20). [*1] 10. Air hose
4) Remove air conditioner compressor (21), 1) Disconnect dust indicator connector (CN-
move it outward and fix it to the machine M11) (25).
with wires. 2) Remove the air hose and pipe assembly
(26).
9. Exhaust pipe
1) Remove heat insulation plate (22) and 11. Remove the left aftercooler hose, pipe (27) and
heat insulation cover (23). radiator hose (28).
13. Fan
Remove fan (31) from fan coupling (30).
a Leave the fan on the radiator side.
HM400-2 7
SEN01443-00 50 Disassembly and assembly
14. Remove radiator lower hose (32). 18. Remove heater hose (36) from the top of the
engine.
15. Remove alternator front cover (33).
8 HM400-2
50 Disassembly and assembly SEN01443-00
21. Disconnect fuel hose (40) between the fuel 24. Disconnect oil level sensor connector (CNOL)
tank and air intake manifold. (43) on the left side of the oil pan.
a This hose is installed under the heater
hose.
HM400-2 9
SEN01443-00 50 Disassembly and assembly
27. Remove hose (47) coming from the water 29. Engine assembly
pump under the left front of the engine. Using sling [1], remove engine assembly (50).
[*3]
4 : Engine assembly: 1,700 kg
10 HM400-2
50 Disassembly and assembly SEN01443-00
[*3]
q If the engine assembly, transmission and
torque converter assembly or drive shaft was
removed, align the engine and transmission in
the lateral direction.
1) Install tool A4 to the coupling on the
engine side and that on the torque con-
verter side.
2) Apply scales [1] on the right and left sides Refilling with coolant
of tool A4. q Add coolant up to the coolant filler of the radia-
3) Measure clearances (a), (b) and between tor. Run the engine to circulate the coolant
scale [1] and tool A4 on the right and left through the system. Then, check the coolant
sides. level in the reservoir tank again.
a Check that the widest clearance on
both sides is 3 mm or less. Refilling with oil
(If the clearance is not in parallel, q Add oil(EO30-CD) to the specified level.
check that the clearance at the widest
part is 3 mm or less.)
a If the level difference is larger than 3
mm, reduce it by moving the torque
converter and transmission assembly.
HM400-2 11
SEN01443-00 50 Disassembly and assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
6 795-125-1210 Thickness gauge t 1
A Angle tightening
7 790-331-1110 t 1
wrench
Removal
k Disconnect the cable from the negative (–) 5. Remove plate (5) and hose assembly (4).
terminal of the battery.
2. Engine undercover
Remove the engine undercover.
12 HM400-2
50 Disassembly and assembly SEN01443-00
7. Remove the upper tank end of radiator upper 9. Remove exhaust pipe (11).
tank hose (7).
HM400-2 13
SEN01443-00 50 Disassembly and assembly
4) Remove bracket (15). 12. Remove EGR gas pressure tube (19).
5) Remove EGR pipe (16). a This tube must be removed since it
a Remove the EGR pipe and EGR becomes an obstacle when the No. 1 cyl-
valve together. inder head cover is removed.
11. Turbocharger lubrication tube 13. Tube between exhaust manifold and EGR
1) Remove turbocharger lubrication tube cooler
(17). 1) Remove heat insulation plate (20).
2) Remove tube (21) between exhaust mani-
fold and EGR cooler.
14 HM400-2
50 Disassembly and assembly SEN01443-00
2) Sling turbocharger and exhaust manifold 17. Oil filter head assembly
assembly (23) temporarily and then 1) Remove 2 oil filter head tubes (27).
remove the mounting bolts and lift off the 2) Remove oil filter head assembly (28).
assembly. [*1]
HM400-2 15
SEN01443-00 50 Disassembly and assembly
16 HM400-2
50 Disassembly and assembly SEN01443-00
26. Remove common rail bracket (40), related 29. Cylinder head cover
clamp (41) and 6 fuel high pressure tube (42). Remove the mounting bolts and each cylinder
[*3] head cover (45). [*6]
27. Remove fuel return tube (43). [*4] 30. Rocker arm and shaft assembly
1) Remove the 3 mounting bolts and rocker
arm and shaft assembly (46). [*7]
a Loosen locknut (48) and loosen
adjustment screw (49) 2 – 3 turns so
that an excessive force will not be
applied to push rod (47) when the
rocker arm is installed.
HM400-2 17
SEN01443-00 50 Disassembly and assembly
18 HM400-2
50 Disassembly and assembly SEN01443-00
Installation [*3]
1. Before installing the high-pressure pipe, check
q Carry out installation in the reverse order to the following.
removal. If there is any defect, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
[*1] q Check the taper seal of the connecting
a Tighten the bolts in the order shown in the fol- part (Part (a): Part of 2 mm from the end)
lowing figure. for visible lengthwise slit (b) and dent (c).
3 Turbocharger mounting bolt:
q Check part (d) (end of the taper seal: Part
44.1 – 49 Nm {4.5 – 5.0 kgm} at 2 mm from the end) for stepped-type
a Tighten the exhaust manifold mounting bolts in wear (fatigue) which your nail can feel.
the following order.
1) Tighten bolts [1] – [3] in numeric order.
2) Tighten other bolts [4] – [24] in numeric order.
3 Exhaust manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
HM400-2 19
SEN01443-00 50 Disassembly and assembly
3. Tighten all of clamps (3), (4), (5) and (6) with [*6]
the fingers and check that they are tightened Fit the O-ring and install cylinder head cover (9).
normally and then tighten them permanently. a Tighten the bolts at the front of the intake man-
a Install clamps (3), (4) and (5) after install- ifold temporarily since they are also used to fix
ing the intake manifold. the wiring harness clamp.
3 High-pressure pipe sleeve nut: 3 Cylinder head cover:
39.2 – 49 Nm {4 – 5 kgm} 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
3 Clamp bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[*7]
1. Install rocker arm and shaft assembly (10) and
[*4] tighten mounting bolts (11), (12) and (13).
3 Fuel return tube joint bolt: a Note that the stem lengths of mounting
9.8 – 12.7 Nm {1.0 – 1.3 kgm} bolts (11), (12) and (13) are different.
Mounting bolt (11): 120 mm
Mounting bolt (12): 90 mm
Mounting bolt (13): 75.2 mm
a Check that the ball of the adjustment
screw is fitted to the socket of the push
rod securely.
3 Rocker arm mounting bolt:
93 – 103 Nm {9.5 – 10.5 kgm}
[*5]
3 Coolant return tube joint bolt (air bleeding):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
20 HM400-2
50 Disassembly and assembly SEN01443-00
HM400-2 21
SEN01443-00 50 Disassembly and assembly
[*9] [*11]
Install push rod (25). a Install the cylinder head according to the fol-
a Check that the push rod is fitted in the cam fol- lowing procedure.
lower. 1. Check that the cylinder head mounting face
and inside of the cylinder are free from foreign
matter, and then set cylinder head gasket (27).
a When fitting the gasket, check that the
grommets are fitted correctly.
[*10]
1. Adjust the crosshead according to the follow-
ing procedure.
1) Loosen the locknut and return the adjust-
ment screw a little. 2. Before tightening the cylinder head mounting
2) While pressing the top of crosshead (26) bolts, check the following.
lightly, tighten the adjustment screw.
3) After the adjustment screw touches the 3. Before tightening the cylinder head mounting
valve stem, tighten it further by 20°. bolts, check the following item.
4) Tighten the locknut. 1) Check the cylinder head mounting bolts.
3 Locknut: 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm} If they are out of the standard, do not use
them but replace them.
q Number of tightening times must be 5
or less (Number of punch marks
denoting the number of tightening
times must be 5 or less).
q Stem length of bolt (Using limit) (b)
Short bolt:170.8 mm
Long bolt:205.8 mm
22 HM400-2
50 Disassembly and assembly SEN01443-00
4. Install cylinder head assembly (29) and tighten a When not using tool A7, make marks (g)
mounting bolts (28) and auxiliary bolts. and (h) on the bolts and cylinder head with
2 Mounting bolt: paint, and then tighten the bolts by 90 +30°
+0
Molybdenum disulfide grease (LM-P) a After tightening bolts [1] – [6], tighten bolt
[7].
a After tightening each bolt, make a punch
mark on its head to indicate the number of
tightening times.
a When a new bolt is used, do not make a
punch mark on its head.
a Do not tighten each bolt more than 6 times
(The number of punch marks on its head
must be 5 or less).
3 Bolt [7]: 66.6 ± 7.4 Nm {6.8 ± 0.8 kgm}
3 Mounting bolt:
a Tighten the mounting bolts in the order of
[1] – [6] as shown below.
1st time: 137 – 157 Nm {14 – 16 kgm}
2nd time:284 – 294 Nm {29.0 – 30.0 kgm}
3rd time: Using tool A7, tighten the bolts by
90 +30°
+0
HM400-2 23
SEN01443-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
A6 795-125-1210 Thickness gauge t 1
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
24 HM400-2
50 Disassembly and assembly SEN01443-00
7. Fuel injector [*4] 7) Insert small L-shaped bar [1] under con-
1) Remove 2 nuts (37) of the solenoid valve nector (46) of fuel injector (45) and pry fuel
of fuel injector (36). injector (45) out.
a Loosen nuts (37) alternately. a At this time, move the high-pressure
2) Pull out spring clamp (38). pipe outward so that its taper seal will
3) Remove the bolts of clamp (39). not interfere with the injector.
4) Remove bolt (42) and holder (41). a Do not grip and pull out the solenoid
5) Push in connector (40) and remove the valve at the top of fuel injector (45)
injector wiring harness. with pliers etc.
a An O-ring is fitted to connector (40).
HM400-2 25
SEN01443-00 50 Disassembly and assembly
Installation 3. Tighten all of clamps (3), (4), (5) and (6) with
the fingers and check that they are tightened
q Carry out installation in the reverse order to normally and then tighten them permanently.
removal. a Install clamps (3), (4) and (5) after install-
ing the intake manifold.
3 High-pressure pipe sleeve nut:
[*1]
1. Before installing the high-pressure pipe, check 39.2 – 49 Nm {4 – 5 kgm}
3 Clamp bolt:
the following.
If there is any defect, it can cause fuel leakage. 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
Accordingly, replace the high-pressure pipe.
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
[*2]
Fit the O-ring and install cylinder head cover (9).
a Tighten the bolts at the front of the intake man-
ifold temporarily since they are also used to fix
the wiring harness clamp.
3 Cylinder head cover:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2. Tighten sleeve nuts (1) and (2) of the fuel injec-
tion by 2 turns with the fingers and then tighten
them with a spanner.
a If a sleeve nut does not catch well, press
its end with another spanner and turn it
with the spanner.
a Tighten the sleeve nuts with spanner-type
torque wrench [1].
26 HM400-2
50 Disassembly and assembly SEN01443-00
HM400-2 27
SEN01443-00 50 Disassembly and assembly
[*4]
1. Install the fuel injector according to the follow-
ing procedure.
a Check that there is not dirt in the injector
sleeve.
1) Install the gasket and O-ring to the fuel
injector.
2) Insert holder (21) in fuel injector (20) and
insert the injector and holder similarly,
directing injector connector (24) toward
the high-pressure pipe insertion hole.
3) Install the spherical washer to bolt (22)
and temporarily tighten holder (21).
2 Spherical washer:
Engine oil (EO30)
4) Insert high-pressure pipe sleeve (23)
through the high-pressure pipe insertion
part, setting it to injector connector (24),
and tighten it temporarily.
a Tighten the sleeve nut on the com-
mon rail side, too, and take care that
the high-pressure pipe will not slant.
5) Tighten holder (21) permanently.
a While pulling the high-pressure pipe
and injector in the opposite directions,
tighten bolt (22).
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the holder, remove
the high-pressure pipe and install the
other injectors in order similarly to the
above.
28 HM400-2
50 Disassembly and assembly SEN01443-00
Removal
1. Drain the coolant.
2. Engine undercover
Remove the engine undercover.
HM400-2 29
SEN01443-00 50 Disassembly and assembly
8. Remove shroud (7), move it backward, and fix 11. Remove lower hose (10) between the right and
it. left radiators.
9. Lift off radiator upper cover (8). 12. Remove the hose and pipe assembly (11)
between the left radiator and lower tank.
30 HM400-2
50 Disassembly and assembly SEN01443-00
HM400-2 31
SEN01443-00 50 Disassembly and assembly
Removal
1. Drain the coolant
a The coolant must be drained since the
upper hose between the right left radiators
will be removed.
32 HM400-2
50 Disassembly and assembly SEN01443-00
HM400-2 33
SEN01444-00
HM400-2
HM400-2 1
SEN01444-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-201-2210 Plate t 1
790-201-2740 Spacer t 1
791-600-1120 Bolt t 1
790-101-2540 Washer t 1
B 1 01580-01613 Nut t 1
3. Hoist and steering pump
01643-31645 Washer t 2 1) Disconnect suction pipes (3) and (4) and
Puller hoses (5), (6), and (7).
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Hydraulic pump t 1
792-420-1110 Centering tool t 1
792-420-1120 • Flange 2
C 2
792T-413-1120 • Collar 1
01050-31230 • Bolt 8
Removal
k Disconnect the cable from the negative (–)
terminal of the battery.
2 HM400-2
50 Disassembly and assembly SEN01444-00
4. Brake cooling and differential lock pump 5. Drive shaft between engine and transmis-
(machine with differential lock differential) sion
1) Disconnect suction pipe and hose (10) Remove guard bracket (15) from the output
and (11) and discharge hoses (12) and shaft cover and disconnect drive shaft (16)
(13). between the engine and transmission. [*1]
4 Drive shaft between engine and trans-
mission: 55 kg
HM400-2 3
SEN01444-00 50 Disassembly and assembly
8. Output shaft
Using forcing screw [1] and guide bolt [2],
remove output shaft (21). [*4]
9. Bearing
Remove bearing (22). [*5]
4 HM400-2
50 Disassembly and assembly SEN01444-00
Installation [*3]
q Carry out installation in the reverse order to Raise the cover and set to the output shaft, use tool
removal. B1 to press fit the inner bearing, then install cover
(20).
[*1]
q 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.
a Using tool C2, align the engine and torque con-
verter with each other.
[*4]
2 Output shaft mounting bolt: Adhesive (LT-2)
3 Output shaft mounting bolt:
98.0 – 123.0 Nm {10 – 12.5 kgm}
[*5]
2 Mounting bolts of drive shaft between engine 2 Bearing: Coat whole surface of bearing
and transmission: inside diameter and shaft out-
Adhesive (LT-2) side diameter with ENS grease.
3 Mounting bolts of drive shaft between engine
and transmission:
98 – 123 Nm {10 – 12.5 kgm}
[Target: 113 Nm {11.5 kgm}]
[*2]
2 Spline: ENS grease
a Before using ENS grease, remove all other
grease completely. Do not mix ENS grease with
other grease. (Use different grease guns for
each type of grease.)
a ENS grease Part No.: 427-12-11871 (2kg can)
2 Bearing cover mounting bolt:
Adhesive (LT-2)
3 Bearing cover mounting bolt:
98.0 – 123.0 Nm {10 – 12.5 kgm}
HM400-2 5
SEN01444-00 50 Disassembly and assembly
Disassembly
1. Oil cage assembly
Remove oil seal (1) from cage (2).
2. Cover assembly
Remove bearing (3) from cover (4).
6 HM400-2
50 Disassembly and assembly SEN01444-00
3 Mounting bolt:
110.3 ± 12.3 Nm {11.25 ± 1.25 kgm}
HM400-2 7
SEN01444-00 50 Disassembly and assembly
8 HM400-2
50 Disassembly and assembly SEN01444-00
New/Remodel
Disconnect brake hoses (3) 5 pieces (on the
Necessity
Sym-
Part No. Part name brake valve side).
Sketch
bol
a Before disconnecting, make match marks.
Q'ty
a Before removing the clamps, check the
792-420-1110 Centering tool t 1 positions of the hoses.
792-420-1120 • Flange 2
C 2 8. Steering hoses
792T-413-1120 • Collar 1
Disconnect steering hoses (5) 5 pieces.
01050-31230 • Bolt 8
a Before disconnecting, make match marks.
1. Discharging the air conditioner gas. [*1] 10. Operator's cab lift cylinder
Remove the connecting pin on the cab side
2. Drain the coolant. and disconnect operator's cab lift cylinder (62).
HM400-2 9
SEN01444-00 50 Disassembly and assembly
11. Operator's cab assembly 2) Disconnect right rear brake hoses (9) and
Pull mounting pins (6) on both sides of the rear (10).
section outward and lift off operator's cab
assembly (7). [*2]
a Loosen the muffler cover mounting bolts
and shift the muffler cover so that the
mounting pin will not interfere with it.
a Do not remove the pins, but just move
them outward.
4 Operator's cab assembly: 1,300 kg
10 HM400-2
50 Disassembly and assembly SEN01444-00
14. Frame and hose assembly 17. Centralized oil pressure pickup hoses
Remove frame and hose assembly (14). Disconnect centralized oil pressure pickup
hoses (24) 5 pieces.
HM400-2 11
SEN01444-00 50 Disassembly and assembly
19. Hoist and steering pump 2) Lift off brake cooling and differential lock
1) Disconnect suction pipes (31) and (32) pump assembly (42). (machine with differ-
and hoses (33), (34), and (35). ential lock differential)
4 Brake cooling and differential lock
pump assembly:
30 kg (Machine with differential lock differential)
20 kg (Machine with limited slip differential)
12 HM400-2
50 Disassembly and assembly SEN01444-00
22. Torque converter and transmission charge 23. Subtank pipe (Tank for brake)
pump hoses, differential lock hoses, brake Disconnect subtank (tank for the brake) pipe
hoses, and brake cooling hoses (55).
1) Disconnect torque converter and trans- a Remove the pipe coupling.
mission charge pump hoses (45) and (46),
differential lock hoses (47) - (49) (only
machine with differential lock differential),
and brake cooling hose (50).
2) Disconnect brake hoses (51) and (52).
HM400-2 13
SEN01444-00 50 Disassembly and assembly
[*2]
q Standard clearance (a) for operator's cab mount-
ing pin: 0.2 mm (on each side)
14 HM400-2
50 Disassembly and assembly SEN01444-00
[*6]
q Standard shim thickness (b) for front mounting
bolt: 1 mm
q Standard shim thickness (c) for rear mounting
bolt: 2 mm.
HM400-2 15
SEN01444-00 50 Disassembly and assembly
Coupling
[*1]
Adjust the speed sensor. For details, see "Testing
and adjusting."
[*2]
2 Front differential mounting bolt:
3. Front output shaft speed sensor of trans- Adhesive (LT2)
4
mission
Front differential mounting bolt:
Remove cover (3) and speed sensor (4). [*1]
490 – 608 Nm {50 – 62 kgm}
16 HM400-2
50 Disassembly and assembly SEN01444-00
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-501-5000 Unit repair stand t 1
790-501-5200 Unit repair stand t 1
1
C 790-901-2110 Bracket t 1
792T-413-1110 Plate t 1 N Q
3 792-103-5110 Wrench t 1
Disassembly
1. P.T.O. assembly 3. Turbine and clutch assembly
Using eyebolt [1], tighten forcing screw [2] to 1) Set torque converter assembly (4) to tool
remove P.T.O. assembly (1). C1.
HM400-2 17
SEN01444-00 50 Disassembly and assembly
3) Using eyebolt [5], remove turbine and 2) Using puller [6], remove inner race (9) and
clutch assembly (6). pump assembly (10).
a For further disassembly, see "7. Dis-
assembly of turbine and clutch
assembly".
4. Stator assembly
Lift up and remove stator assembly (7).
a For further disassembly, see "8. Disassem-
bly of stator assembly".
5. Pump assembly
1) Using tool C3, remove nut (8).
18 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 19
SEN01444-00 50 Disassembly and assembly
20 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 21
SEN01444-00 50 Disassembly and assembly
8) Install plate (21) and snap ring (20). 3) Install the seal ring (17).
2 Seal ring: Grease (G2-LI)
4) Using the push tool, press fit inner race
(15).
22 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 23
SEN01444-00 50 Disassembly and assembly
8. P.T.O. assembly
Fit the O-ring and install P.T.O. assembly (1),
using eyebolt [1].
24 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 25
SEN01444-00 50 Disassembly and assembly
11. Coupling
1) Remove rear coupling (15).
13. Covers
Remove covers (18) (on the 1st clutch side)
2) Remove input coupling (27). and (19) (on the 2nd clutch side).
a Check the thickness and quantity of the
shims on the cover (19) side.
26 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 27
SEN01444-00 50 Disassembly and assembly
19. R and FL clutch assembly 1] Remove snap ring (201), then remove
Remove R and FL clutch assembly (25). bearing and spacer and snap ring
a For further disassembly of the R and FL assembly (202).
clutch assembly, see "step 26".
2) Disassemble the cage assembly accord- 3] Remove bearing outer race (38b)
ing to the following procedure. from cage (211).
28 HM400-2
50 Disassembly and assembly SEN01444-00
21. P.T.O. assembly 2) Disassemble the gear and shaft and ring
Remove P.T.O. assembly (28). gear assembly according to the following
a For further disassembly of the P.T.O. procedure.
assembly, see "step 28". 1] Using push tool [15], remove shaft
and ring gear assembly (31).
HM400-2 29
SEN01444-00 50 Disassembly and assembly
3] Remove snap rings (36) and (68) 4) Remove snap ring (41).
from shaft (35).
a Snap ring (68) is for the oil sump.
30 HM400-2
50 Disassembly and assembly SEN01444-00
7) Remove front shaft and hub assembly 9) Remove end plate (55), discs (56) 7
(49). pieces, plate (57) 7 pieces, and wave
springs (58) 7 pieces from the differential
clutch.
HM400-2 31
SEN01444-00 50 Disassembly and assembly
11) Remove seal ring (61) from piston (60). 24. Disassembly of 2nd and 3rd clutch assem-
bly (2nd clutch side)
1) Remove seal rings (71) 3 pieces.
32 HM400-2
50 Disassembly and assembly SEN01444-00
4) Remove gear and needle roller bearing 7) Remove end plate (80), plates (81) 14
assembly (76). pieces, discs (82) 13 pieces, and wave
springs (83) 13 pieces from the 2nd clutch.
HM400-2 33
SEN01444-00 50 Disassembly and assembly
9) Remove seal rings (88) and (89) from pis- 12) Remove gear and needle roller bearing
ton (87). assembly (104).
(3rd clutch side) 13) Remove needle roller bearing (106) from
10) Using push puller [6], remove bearing gear (105).
inner race (100a) and spacer (101).
a For bearing outer race (100b), see
"Disassembly of transmission case
assembly on torque converter side".
34 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 35
SEN01444-00 50 Disassembly and assembly
36 HM400-2
50 Disassembly and assembly SEN01444-00
8) Using the hanging tap, remove thrust wash- a For bearing outer race (141b), see
ers (134) and piston assembly (136). "Disassembly of transmission case
assembly on torque converter side".
HM400-2 37
SEN01444-00 50 Disassembly and assembly
38 HM400-2
50 Disassembly and assembly SEN01444-00
26. Disassembly of R and FL clutch assembly 4) Using C-clamp [11], etc., compress the
(R clutch side) clutch spring and remove snap ring (168).
1) Remove seal rings (161) 3 pieces. a The clutch spring may be com-
pressed by holding the end plate with-
out using the C-clamp similarly to the
2nd clutch. (For example, put a bar to
the screw hole of the shaft and press
down the end plate with the spacer.).
HM400-2 39
SEN01444-00 50 Disassembly and assembly
5) Remove end plate (169), plates (170) 12 7) Remove seal rings (176) and (177) from
pieces, discs (171) 11 pieces, and wave piston (175).
springs (172) 11 pieces from the R clutch.
40 HM400-2
50 Disassembly and assembly SEN01444-00
10) Remove needle roller bearing (184) 2 pieces 12) Remove end plate (186), plates (187) (12
from gear (183). pieces), discs (188) 11 pieces, and wave
springs (189) 11 pieces from the FL clutch.
HM400-2 41
SEN01444-00 50 Disassembly and assembly
14) Remove seal rings (193) and (194) from 28. Disassembly of transmission case assem-
piston (192). bly (on torque converter side)
Remove bearing outer races (64b), (100b), and
(141b) from the case.
42 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 43
SEN01444-00 50 Disassembly and assembly
2) Set bearing inner race (222d) in position 2) Fit collar (218) and install bearings (215)
and install P.T.O. gear (221) and press fit it and (216) to gear (214) by expansion fit.
by tightening nut (219). a Take care of the installing direction.
2 Bolt: Adhesive (LT-2) 3) Install snap ring (217).
3 Bolt: 4) Install gear assembly (214) by shrink fit.
313.8 – 392.3 Nm {32 – 40 kgm} a Shrink fit temperature: Approx. 120°C
for 30 minutes
5) Install holder (213) and tighten the bolts
2 Bolt: Adhesive (LT-2)
3 Bolt:
245 – 309 Nm {25 – 31.9 kgm}
44 HM400-2
50 Disassembly and assembly SEN01444-00
2) Install piston assembly (191) and thrust 4) Install needle roller bearing (184) 2 pieces
washer (190). to gear (183).
2 Apply engine oil (EO-30CD) to the
periphery and contact surfaces of
the seal rings.
HM400-2 45
SEN01444-00 50 Disassembly and assembly
(R clutch side)
10) Install seal rings (176) and (177) to piston
8) Install gear and needle roller bearing assem- (175).
bly (182), thrust washer (181), and spacer a Install the seal rings with the pressure
(180) (2-piece type). receiving side directed to the housing.
a If the gear and needle roller bearing
assembly (182) is difficult to install,
repeat the procedure from step 5).
a The gear and needle roller bearing
assembly (182) may be installed first.
Then, compress the clutch spring with
C-clamp [11] and install snap ring
(180).
46 HM400-2
50 Disassembly and assembly SEN01444-00
11) Install piston assembly (174) and thrust 13) Install needle roller bearing (167) 2 pieces
washer (173). to gear (166).
2 Apply engine oil (EO-30CD) to the
periphery and contact surfaces of
the seal rings.
HM400-2 47
SEN01444-00 50 Disassembly and assembly
16) Using C-clamp, jig [11], etc., compress the 19) Install seal rings (161) 3 pieces.
clutch spring and install snap ring (168).
a The clutch spring may be com-
pressed by holding the end plate with-
out 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.)
17) Install gear and needle roller bearing assem- 2) Install piston assembly (152) and thrust
bly (162), thrust washer (165), and spacer washer (151).
(164). a Using the hanging tap, install piston
a If gear and needle roller bearing assem-
assembly (152), taking extreme care
bly (162) is difficult to install, repeat the
procedure from step 14). that the seal rings will not be caught.
18) Install bearing inner race (163a) by shrink fit. 2 Apply engine oil (EO-30CD) to the
48 HM400-2
50 Disassembly and assembly SEN01444-00
3) Install plates (148) 10 pieces, discs (149) 5) Install gear and needle roller bearing
9 pieces, wave springs (150) 9 pieces, assembly (140) temporarily and match the
and end plate (147) to the FH clutch. grooves of the discs.
a Dip the discs in clean engine oil (EO- a Pressing down the assembly, turn it to
30CD) for at least 2 minutes before the right and left and push it in gradu-
installing. ally so that it will not collide with the
crests of the discs.
HM400-2 49
SEN01444-00 50 Disassembly and assembly
8) Install gear and needle roller bearing 11) Install piston assembly (136) and thrust
assembly (140), thrust washer (143), and washer (134).
spacer (142). a Using the hanging tap, install piston
a If the gear and needle roller bearing assembly (136), taking extreme care
assembly (140) is difficult to install, that the seal rings will not be caught.
repeat the procedure from step 5). 2 Apply engine oil (EO-30CD) to the
periphery and contact surfaces of
the seal rings.
50 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 51
SEN01444-00 50 Disassembly and assembly
18) Install thrust washer (125) and snap ring 6. Assembly of 2nd and 3rd clutch assembly
(124). (3rd clutch side)
1) Install seal rings (115) and (116) to piston
(114).
a Install the seal rings with the pressure
receiving side directed to the housing.
52 HM400-2
50 Disassembly and assembly SEN01444-00
3) Install plates (109) 8 pieces, discs (110) 7 5) Install gear and needle roller bearing assem-
pieces, wave springs (111) 7 pieces, and bly (104) temporarily and match the grooves
end plate (108) to the 3rd clutch. of the discs.
a Dip the discs in clean engine oil (EO- a Pressing down the assembly, turn it to
30CD) for at least 2 minutes before the right and left and push it in gradu-
installing. ally so that it will not collide with the
crests of the discs.
6) Remove gear and needle roller bearing
assembly (104) again.
HM400-2 53
SEN01444-00 50 Disassembly and assembly
8) Install gear and needle roller bearing assem- 12) Install piston assembly (86) and thrust
bly (104). washer (84).
a If it is difficult to install the gear and a Using the hanging tap, install piston
need le rol ler bearing assem bly, assembly (86), taking extreme care
repeat the procedure from 5). that the seal rings will not be caught.
9) Install thrust washer (103) and snap ring 2 Apply engine oil (EO-30CD) to the
(102). periphery and contact surfaces of
the seal rings.
54 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 55
SEN01444-00 50 Disassembly and assembly
19) Install gear (72), spacer (227) (2-piece 7. Assembly of differential clutch assembly
type), and spacer (226) (having a spline). 1) Assemble the housing assembly accord-
ing to the following procedure.
1] Using push tool [12], press fit bearing
inner race (65a) to housing (62).
a For bearing outer race (65b), see
"Disassembly of transmission
case assembly on torque con-
verter side".
56 HM400-2
50 Disassembly and assembly SEN01444-00
2) Install seal ring (61) to piston (60). 2] Install hub (52) to shaft (51), then
2 Apply grease (G2-LI) to the seal install snap ring (50).
ring. 3] Install seal rings (53) and (54).
a Install the seal ring with the pressure 2 Apply grease (G2-LI) to the seal
receiving side directed to the housing. rings.
HM400-2 57
SEN01444-00 50 Disassembly and assembly
58 HM400-2
50 Disassembly and assembly SEN01444-00
10) Install sun gear (40) and snap ring (39). 3] Using push tool [16], press fit bearing
outer race (34-2b) to gear (37).
a Bearing (34) [Inner races (34-1),
(34-2), (34-3)] is the assembly
No.
2] Using push tool [15], press fit bearing 5] Set the snap ring side of shaft and
inner race (38a) to gear. s n ap r in g a s s em bl y ( 32 ) as th e
a For bearing outer race (38b), see receiver and press fit (install) ring
the section of bearing cage. gear (33) and bearing inner race (34-
2a) together, using push tool [17].
HM400-2 59
SEN01444-00 50 Disassembly and assembly
60 HM400-2
50 Disassembly and assembly SEN01444-00
2] Using push tool [19], press fit bearing 2) Install cage assembly (26).
(205) to spacer (204) and install snap 2 O-ring on mating face:
ring (203). Grease (G2-LI)
HM400-2 61
SEN01444-00 50 Disassembly and assembly
12. 1st and FH clutch assembly and 2nd and 14. Shroud
3rd clutch assembly Install shroud (90).
Sling and install 1st and FH clutch assembly a Press the shroud lightly against the hous-
(23) and 2nd and 3rd clutch assembly (24) ing, then separate it from the housing by 1
simultaneously. mm and install it.
a For assembly of the 1st and FH clutch
assembly, see "5". For assembly of the
2nd and 3rd clutch assembly, see "6".
2 Apply grease (G2-LI) to the seal rings 6
places before installing transmission
case assembly (21) (on the opposite side
of the torque converter).
a Check that the cuts of the seal rings 6
places are not opened.
62 HM400-2
50 Disassembly and assembly SEN01444-00
2) Bearing cage (Rear output side) 2) Install bearing cages (19) and (20) without
Using push tool [20], press fit oil seal (68) shims.
to bearing cage (66). 3 Mounting bolt:
a Adjust distance (f) from the cage end 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
to 28.5 ± 0.2 mm. 3) Rotate the output shaft 20 turns.
4) Check that the tightening torque of the
mounting bolt has not changed. If it has
changed, repeat steps 2) and 3).
5) Loosen the mounting bolts of bearing
cage (19) and measure the rotating torque
of the output shaft.
a Rotating torque:
14.7 – 25.5 Nm {1.5 – 2.6 kgm}
6) Measure clearance (f) between bearing
cage (19) and rear transmission case at 3
places (equally spaced on the periphery)
and obtain the average.
a If the dispersion of the measured val-
3) Using push tool [20], press fit oil seal (67) ues at the 3 places exceeds 0.15 mm,
to bearing cage (66). check the bearing and other parts for
a Adjust distance (g) from the cage end abnormality. Correct any abnormal
to 13.5 ± 0.2 mm. part and measure clearance (f) again.
7) Subtract the following value from the aver-
age of clearance (f) obtained in 6) above.
Insert shims of the thickness equivalent to
the result of this calculation.
a Reduction of thickness:
0.10 – 0.15 mm
a Allowable range of shim thickness
(Reference): 1.7 – 3.0 mm
8) Rotating the output shaft, tighten the
mounting bolts of bearing cage (19) to the
following torque.
3 Mounting bolt:
98 – 122 Nm {10 – 12.5 kgm}
9) Measure the rotating torque of the output
4) Install bearing outer race (38b). shaft and check that its increase from the
value obtained in step 5) is in the following
range.
a Increase of rotating torque
2.94 – 9.81 Nm {0.3 – 1.0 kgm}
HM400-2 63
SEN01444-00 50 Disassembly and assembly
10) Measure clearance (a) between bearing 18. Snap ring of front output shaft
cage (20) and the rear transmission case Install snap ring (16).
at 3 places (equally spaced on the periph-
ery) and obtain the average.
a If the dispersion of the measured val-
ues at the 3 places exceeds 0.15 mm,
check the bearing and other parts for
abnormality. Correct any abnormal
part and measure clearance (a)
again.
11) Subtract the following value from the aver-
age of clearance (a) obtained in 10)
above. Insert shims of the thickness
equivalent to the result of this calculation.
a Reduction of thickness:
0.05 – 0.10 mm
a Allowable range of shim thickness (Ref-
erence): 1.50 – 3.15 mm
12) Rotating the output shaft, tighten the mount-
ing bolts of bearing cage (20) to the following
torque.
3 Mounting bolt:
98 – 122 Nm {10 – 12.5 kgm}
13) Measure the rotating torque of the output
shaft and check that its increase from the
value obtained in step 9) is in the following
range.
a Increase of rotating torque:
2.94 – 9.81 Nm {0.3 – 1.0 kgm}
19. Coupling
1) Install the O-ring, holder, and rear cou-
pling (15).
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
64 HM400-2
50 Disassembly and assembly SEN01444-00
23. Strainer
Install strainer (9).
HM400-2 65
SEN01444-00 50 Disassembly and assembly
29. Piping
Install piping (1)
66 HM400-2
50 Disassembly and assembly SEN01444-00
HM400-2 67
SEN01445-00
HM400-2
HM400-2 1
SEN01445-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-201-2850 Spacer t 1
1 790-201-2740 Spacer t 1
790-201-2750 Spacer t 1
790-101-5401 Push tool kit t 1
790-101-5481 • Plate 1
2
790-101-5421 • Grip 1
H
01010-51240 • Bolt 1
790-201-2770 Spacer t 1
3
792T-423-1130 Push tool t 1 N Q
790-201-2740 Spacer t 1
4 792T-423-1110 Push tool t 1 N Q
792T-423-1120 Push tool t 1 N Q
Disassembly
1. Speed sensor and top cover
Remove speed sensor (1) and top cover (2).
2 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 3
SEN01445-00 50 Disassembly and assembly
4 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 5
SEN01445-00 50 Disassembly and assembly
6 HM400-2
50 Disassembly and assembly SEN01445-00
11] Remove washer (45), pinion gear 8. Disassembly of side carrier and shaft
(46), and bushing (sleeve) (47). assembly
1) Disassemble the side carrier and shaft
assembly on the bevel gear side accord-
ing to the following procedure.
1] Remove seal (49).
HM400-2 7
SEN01445-00 50 Disassembly and assembly
3] Remove bearing (53) and bearing 2> Using push tool [7], remove bear-
outer races (38b) and (51b) from case ing inner race (56a).
(52).
a Bearing (53) is divided into the
inner race and outer race when
the shaft is removed (pulled out).
8 HM400-2
50 Disassembly and assembly SEN01445-00
Assembly
a When installing a seal to another part (particu-
larly 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 assem-
bly
1) Assemble the side carrier and shaft
assembly on the bevel gear side accord-
ing to the following procedure.
1] Install bearing outer races (38b),
(51b), and (53b) to case (52).
3> Adjust the shims for the bearing
according to the following proce-
dure.
a) Measure the starting tangen-
tial force in the tangential
direction of the bolt hole
(ø234) of the case.
a Standard tangential force:
Max. 21.5 N {2.2 kg}
b) If the starting tangential
force is too large, increase
the shims. If the former is
too little, decrease the lat-
te r. T he n , m e a s ur e t h e
2] Shaft and bearing inner race assem- star ting tangenti al fo rc e
bly again.
1> Using tool H4, press fit bearing a If the starting tangential force
inner race (51a) to shaft (59). is tool large, disassemble
shaft and bearing inner race
as sem bly ( 50) an d c as e
assembly (61) and increase
the shims, then execute 2]
above.
HM400-2 9
SEN01445-00 50 Disassembly and assembly
3] Using tool H3, press fit seal (49). 2> Set the standard shims (having
the thickness and quantity
checked when disassembled)
and install coupling (18). Using
push tool [7], press holder (65) to
press fit case assembly (66) to
shaft and bearing inner race
assembly (55).
10 HM400-2
50 Disassembly and assembly SEN01445-00
a The procedure for installing both side carrier 3] Install pinion gear assembly (43) and
and shaft assemblies to the body is explained cross shaft (44) in 1 unit.
in 3 below.
HM400-2 11
SEN01445-00 50 Disassembly and assembly
12 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 13
SEN01445-00 50 Disassembly and assembly
2) Under the above condition, set the stan- 4. Right and left output shaft couplings
dard shim (having the thickness and quan- Install couplings (17) and (18) on both sides.
tity checked when disassembled) and 2 Mounting bolt: Adhesive (LT-2)
install side carrier and shaft assembly (20) 3 Mounting bolt:
on the opposite side. 490 – 608 Nm {50 – 62 kgm}
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
14 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 15
SEN01445-00 50 Disassembly and assembly
16 HM400-2
50 Disassembly and assembly SEN01445-00
(1) Checking tooth contact q In this case, adjust the tooth contact
Apply red lead thinly to the surfaces of 7 - according the following procedure
8 teeth of the bevel gear and turn the
bevel gear in the forward and reverse If bevel pinion is too far from bevel gear
directions, then check the tooth contact a The tooth contact pattern is as fol-
pattern on the bevel gear. lows.
a The center of the tooth contact must q Decrease the shims of the bevel pin-
be as follows. ion to move the bevel pinion in direc-
q Middle of tooth height tion (C).
q Point on tooth at distance of (x) from q Move the bevel gear in direction (D).
small end (C)
(Approx. 33% of tooth length)
a Width (y) of the tooth contact must be
30 - 60% of the tooth length.
a Check that there is not a strong con-
tact at tip (A), bottom (B), small end
(C) or large end (D).
HM400-2 17
SEN01445-00 50 Disassembly and assembly
If bevel gear is too close to bevel pinion 8. Bevel gear supporting bolt
a The tooth contact pattern is as fol- Install bevel gear supporting bolt (4).
lows. a Bring the bolt end in contact with the back
q Decrease the shims of the bevel pin- of the gear, then return it by a half turn and
ion to move the bevel pinion in direc-
tion (C). secure it with the locknut.
q Move the bevel gear in direction (D). 2 Bolt: Gasket sealant (LG-5)
3 Locknut: 196 – 245 Nm {20 – 25kgm}
18 HM400-2
50 Disassembly and assembly SEN01445-00
Removal and installation of center 4. Drive shaft between center differential and
differential assembly 1 rear differential
Remove the guard and disconnect only the
Removal center differential end of drive shaft (3)
between center differential and rear differen-
k Disconnect the cable from the negative (–) tial. [*2]
terminal of the battery.
k Raise the dump body and insert the safety
pin.
1. Draining oil
Drain oil from the center differential case and
center final drive case.
HM400-2 19
SEN01445-00 50 Disassembly and assembly
[*2]
a When installing the drive shaft, check that the
key way of the spider cap is matched to that of
8. Center differential assembly the mating yoke and tighten the bolts.
2 Mounting bolt of drive shaft between center
Sling center differential (15) temporarily. Using
forcing screws (M14 x 2), pull out the center differential and rear differential:
differential. After pulling out the differential Adhesive (LT-2)
3 Mounting bolt of drive shaft between center
halfway, change the slinging position (increase
the number of slings) and remove the differen- differential and rear differential:
tial. [*4] 98 – 123 Nm {10 – 12.5 kgm}
[Target: 113 Nm {11.5 kgm}]
4 Center differential assembly: 380 kg
[*3]
a When installing a seal to a cover, use a push
tool matched to the diameter of that seal.
2 Seal lip: Grease (G2-LI)
3 Cover mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
20 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 21
SEN01445-00 50 Disassembly and assembly
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
5 792T-423-1130 Push tool t 1 N Q
792-103-0901 Wrench t 1
6 792-222-1110 Adapter t 2
795-525-1000 Micrometer t 1
796-751-1500 Wrench assembly t 1
7 3. Transfer input coupling and holder
795-630-1803 Torque wrench t 1
Remove holder (2) and coupling (3).
8 792T-422-1250 Push tool t 1 N Q
790-501-5000 Unit repair stand t 1
790-501-5200 Unit repair stand t 1
H 9
790-901-2110 Bracket t 1
793-310-2141 Plate t 1 R Q
792T-423-1140 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
11 790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1 4. Cage
1) Using forcing screw [1], remove cage
Disassembly assembly (4).
a Check the thickness and quantity of
1. Set the center differential gear assembly to tool the shims.
H9.
22 HM400-2
50 Disassembly and assembly SEN01445-00
2) Remove side seal (5), oil seal (6), and 6. Input shaft holder
bearing outer race (7b) from cage (12). a Place a wood block, etc. so that the bevel
pinion will not fall.
1) Remove holder (13).
a Check the thickness and quantity of
the shims.
HM400-2 23
SEN01445-00 50 Disassembly and assembly
9. Cage assembly
1) Using forcing screw [3], remove cage
assembly (21).
a Check the thickness and quantity of
the shims.
24 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 25
SEN01445-00 50 Disassembly and assembly
26 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 27
SEN01445-00 50 Disassembly and assembly
28 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 29
SEN01445-00 50 Disassembly and assembly
30 HM400-2
50 Disassembly and assembly SEN01445-00
2) Cage assembly
1] Install bearing outer race (23b) to
cage (22).
HM400-2 31
SEN01445-00 50 Disassembly and assembly
32 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 33
SEN01445-00 50 Disassembly and assembly
3) Adjusting tooth contact of bevel gear and (2) Adjusting tooth contact
bevel pinion If the tooth contact pattern is not proper,
q When the backlash is below standard adjust the tooth contact according to the
value procedure shown in the following page.
Loosen the adjustment nut on the bevel a After adjusting the tooth contact,
gear side and tighten the adjustment nut check the backlash again.
on the right side by the same angle (to
move the bevel gear in the direction of A). If bevel pinion is too far from bevel gear
a The tooth contact pattern is as fol-
q When the backlash is above standard lows.
value q Decrease the shims of the bevel pin-
Loosen the adjustment nut on the left side ion to move the bevel pinion in direc-
and tighten the adjustment nut on the tion (C).
bevel gear side by the same angle (to q Move the bevel gear in direction (D).
move the bevel gear in the direction of B).
34 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 35
SEN01445-00 50 Disassembly and assembly
14. Transfer input coupling and holder 16. Bevel gear supporting bolt
Install coupling (3) and holder (2). Install bevel gear supporting bolt (66).
2 End of bearing (Part A): a Bring the bolt end in contact with the back
Grease (G2-LI) of the gear, then return it by a half turn and
2 End of side seal (Part B): secure it with the locknut.
Grease (G2-LI) 2 Bolt: Gasket sealant (LG-5)
2 Holder mounting bolt: Adhesive (LT-2) 3 Locknut:
3 Holder mounting bolt: 196 – 245 Nm {20 – 25kgm}
824 – 1,030 Nm {84 – 105 kgm}
15. Cover
Install cover (1).
36 HM400-2
50 Disassembly and assembly SEN01445-00
1. Draining oil
Drain oil from the rear differential case and
rear final drive case.
HM400-2 37
SEN01445-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a 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.
2 Mounting bolt of drive shaft between center
differential and rear differential:
Adhesive (LT-2)
3 Mounting bolt of drive shaft between center
differential and rear differential:
98 – 123 Nm {10 – 12.5 kgm}
[Target: 113 Nm {11.5 kgm}]
[*2]
2 Rear differential mounting bolt:
157 – 198 Nm {16 – 20 kgm}
[Target: 177 Nm {18 kgm}]
38 HM400-2
50 Disassembly and assembly SEN01445-00
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
5 792T-423-1130 Push tool t 1 N Q
792-103-0901 Wrench t 1
6 792-222-1110 Adapter t 2
795-525-1000 Micrometer t 1
790-501-5000 Unit repair stand t 1
790-501-5200 Unit repair stand t 1
9
790-901-2110 Bracket t 1
H 793-310-2141 Plate t 1 R Q
792T-423-1140 Push tool t 1 N Q
790-101-5421 Grip t 1
01010-51240 Bolt t 1
11 790-101-5401 Push tool kit t 1
790-101-5451 • Plate 1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Disassembly
1. Set the rear differential gear assembly to tool 2) Remove side seal (6) and oil seal (7) from
H9. pinion and cage assembly (5).
HM400-2 39
SEN01445-00 50 Disassembly and assembly
3) Remove pinion assembly (8) from cage 4. Differential gear and differential lock assem-
assembly (9). bly
a Sling the differential case in advance.
1) Remove locks (26) and (27).
2) Using tool H6, loosen adjustment nuts
(28) and (29) to the degree that you can
turn them with fingers.
3) Loosen bolts (30) 4 pieces.
4) Sling the differential gear case assembly
with wires and remove bearing caps (31)
and (32) and nuts (28) and (29), then
remove the differential gear case assem-
bly.
a Take care not to drop the bearing
outer race.
4) Disassembly of pinion assembly
Remove spacer (11) and bearing inner
race (12a) from pinion (10).
40 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 41
SEN01445-00 50 Disassembly and assembly
9] Remove washer (53) and differ- 11] Remove washer (57), pinion gear
ential side gear (54). (58), and bushing (sleeve) (59).
42 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 43
SEN01445-00 50 Disassembly and assembly
2> Install bearing inner race (50a) to 7] Install seal ring (40) to piston
bevel gear and case assembly (39).
(49) by shrink fit. a Take care of the direction of
a Shrink fit temperature: 120°C the seal ring.
for 30 minutes 8] Install seal rings (35) to case
(34).
a Take care of the direction of
the seal rings.
9] Install pin (38) and washer (37).
10] Install piston (39) to case (34).
11] Install the case and piston assem-
bly, matching it to the position of
pin (45).
3 Case mounting bolt:
157 – 196 Nm {16 – 20 kgm}
12] Install seal ring (36) to case (34).
a Take care of the direction of
the seal rings.
13] Install sleeve (42), taking care
3> Install bevel gear assembly (47)
not to damage seal ring (36).
to case (46).
14] Install bearing (41a) to case (34)
a Match the match marks to
by shrink fit.
each other.
a Shrink fit temperature: 120°C
for 30 minutes
44 HM400-2
50 Disassembly and assembly SEN01445-00
3. Caps
1) Install caps (31) and (32) and tighten bolt
(30) temporarily.
2) Using tools [5] and [6], tighten bolt (21).
3 Bolt:
824 – 1,040 Nm {84 – 105 kgm}
HM400-2 45
SEN01445-00 50 Disassembly and assembly
46 HM400-2
50 Disassembly and assembly SEN01445-00
5) Using tool H11, press fit oil seal (7). 7. Input coupling and holder
a Press fit oil seal (7) so that clearance Install coupling (2) and holder (1).
(c) between the periphery of oil seal 2 End of bearing (Part A):
(7) and cage (13) will be 10 ± 0.5 mm. Grease (G2-LI)
2 End of side seal (Part B):
Grease (G2-LI)
2 Holder mounting bolt: Adhesive (LT-2)
3 Holder mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
HM400-2 47
SEN01445-00 50 Disassembly and assembly
8. Adjusting tooth contact and backlash 2) Adjust the tooth contact according to the
q Adjust the backlash and tooth contact following procedure.
simultaneously. 1] Adjust the projection of the bevel pin-
1) Adjust the backlash according to the fol- ion with shim (65) between differential
lowing procedure. case (64) and transfer case (17).
1] Move the bevel gear with the adjust- 2] Adjusting tooth contact
ment nuts (28) and (29). At this time, a See "Adjusting tooth contact" in
rotate the nuts on both sides by the 3] below
same turns in the same direction so
that the preload on the bearing will
not change.
48 HM400-2
50 Disassembly and assembly SEN01445-00
(1) Checking tooth contact If bevel pinion is too close to bevel gear
Apply red lead thinly to the surfaces of 7 – a The tooth contact pattern is as fol-
8 teeth of the bevel gear and turn the lows.
bevel gear in the forward and reverse q Increase the shims of the bevel pinion
directions, then check the tooth contact to move the bevel pinion in direction
pattern on the bevel gear. (E).
a The center of the tooth contact must q Move the bevel gear in direction (F).
be as follows.
q Middle of tooth height
q Point on tooth at distance of (x) from
small end (C)
(Approx. 33% of tooth length)
a Width (y) of the tooth contact must be
30 – 60% of the tooth length.
HM400-2 49
SEN01445-00 50 Disassembly and assembly
50 HM400-2
50 Disassembly and assembly SEN01445-00
HM400-2 51
SEN01446-00
HM400-2
HM400-2 1
SEN01446-00 50 Disassembly and assembly
2. Jacking up
1) Jack up the front (sub) frame and support
it on stand [1], etc.
2) Using jack [2], raise the front axle support.
3. Left fender
Lift of left fender (1).
2 HM400-2
50 Disassembly and assembly SEN01446-00
[*1]
3 Front wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[Target: 926 Nm {94.5 kgm}]
[*2]
q 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.
2 Mounting bolt of drive shaft between front
differential and front final drive:
Adhesive (LT-2)
3 Mounting bolt of drive shaft between front
differential and front final drive:
98 – 123 Nm {10 – 12.5 kgm}
HM400-2 3
SEN01446-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1210 Fixture t 3 N Q
792T-427-1110 Fixture t 3 N Q
1
01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 N Q
J 2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
3 792T-422-1230 Push tool t 1 N Q
792-520-2110 Installer t 1
5 792-530-1600 Push tool t 1
790-434-1620 Installer t 1
Disassembly
1. Drive shaft (1)
Remove drive shaft (1).
a When removing the drive shaft, take care
that its cap (yoke) will not come off.
4. Sun gear
Remove sun gear (5).
4 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 5
SEN01446-00 50 Disassembly and assembly
9. Ring gear
Remove ring gear (16).
6 HM400-2
50 Disassembly and assembly SEN01446-00
2) Disassemble the brake assembly accord- 2> Remove seal rings (28) and (29)
ing to the following procedure. from cylinder (26) and piston (27).
1] Remove tools J1.
HM400-2 7
SEN01446-00 50 Disassembly and assembly
13. Hub (Inner gear) and outer gear 3) Remove floating seal (37a) from floating
1) Remove outer gear (34) from hub (inner seal and cage assembly (36).
gear) (33).
8 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 9
SEN01446-00 50 Disassembly and assembly
2. Hub (Inner gear) and outer gear 4) Using tool J5, install floating seal (37a) to
1) Using tool J5, install floating seal (37b) to cage (46).
outer gear (38). a Measure height (A) at portion (a) of
the seal above the gear, hub, and
ratainer (at 4 places on the periphery)
and check that its dispersion is less
than 1 mm.
10 HM400-2
50 Disassembly and assembly SEN01446-00
7) Install outer gear (34) to hub (inner gear) 2) Assemble the brake assembly according
(33). to the following procedure.
a Take extreme care that the floating 1] Assemble the cylinder assembly ac-
seal will not be damaged or rolled up. cording to the following procedure.
1> Install seal rings (28) and (29) to
cylinder (26) and piston (27).
3. Brake assembly
1) Install disc (32), plate (31), and damper
(end plate) (30).
a When installing the plate, match the 6
cuts on its per.
HM400-2 11
SEN01446-00 50 Disassembly and assembly
2] Install cylinder assembly (25). 4. Place the assembly with the brake side down.
3 Cylinder mounting bolt:
157 – 196 Nm {16 – 20 kgm} 5. Floating seal cage and floating seal
1) Using tool J5, install floating seal (22a) to
cage (21).
a Measure height (A) at portion (a) of
the seal above the gear, hub, and
ratainer (at 4 places on the periphery)
and check that its dispersion is less
than 1 mm.
12 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 13
SEN01446-00 50 Disassembly and assembly
14 HM400-2
50 Disassembly and assembly SEN01446-00
13. Cover
Install cover (2).
3 Cover mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
HM400-2 15
SEN01446-00 50 Disassembly and assembly
16 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 17
SEN01446-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Rear wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[Target: 926 Nm {94.5 kgm}]
18 HM400-2
50 Disassembly and assembly SEN01446-00
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1210 Fixture t 3 N Q
792T-427-1110 Fixture t 3 N Q
1
01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 N Q
2 790-101-5421 Grip t 1
J
01010-51240 Bolt t 1
3 792T-422-1230 Push tool t 1 N Q
4 792T-422-1240 Push tool t 1 N Q
792-520-2110 Installer t 1
5 792-530-1600 Push tool t 1
790-434-1620 Installer t 1
HM400-2 19
SEN01446-00 50 Disassembly and assembly
4. Ring gear
Remove ring gear (9).
20 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 21
SEN01446-00 50 Disassembly and assembly
2) Remove floating seal and cage assembly 4) Remove cover (32) from outer gear (31),
(29) and floating seal (15b) from hub then remove seal (33).
(inner gear) (28).
22 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 23
SEN01446-00 50 Disassembly and assembly
3. Brake assembly
1) Install disc (25), plate (24), and damper
(end plate) (23).
a When installing the plate, match the 6
cuts on its periphery.
24 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 25
SEN01446-00 50 Disassembly and assembly
26 HM400-2
50 Disassembly and assembly SEN01446-00
8. Carrier assembly
1) Assemble the carrier assembly according
to the following procedure.
1] Install bearing (5) and planetary gear
(4).
2] Install shaft (2).
a Take care not to lose ball (3).
HM400-2 27
SEN01446-00 50 Disassembly and assembly
4. Rear wheel
Sling the rear wheels (1) temporarily and 6. Sun gear and drive shaft
remove the mounting bolts to remove rear Remove the rear final drive cover and sun gear
wheels (1). [*1] and drive shaft (4).
28 HM400-2
50 Disassembly and assembly SEN01446-00
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
3 Rear wheel mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
[Target: 926 Nm {94.5 kgm}]
HM400-2 29
SEN01446-00 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
792T-422-1210 Fixture t 3 N Q
792T-427-1110 Fixture t 3 N Q
1
01010-61435 Bolt t 3
01010-62440 Bolt t 3
792T-422-1220 Plate t 1 N Q
J 2 790-101-5421 Grip t 1
01010-51240 Bolt t 1
3 792T-422-1230 Push tool t 1 N Q
792-520-2110 Installer t 1
5 792-530-1600 Push tool t 1
790-434-1620 Installer t 1
Disassembly
a The sun gear was removed when the final
3. Retainer and shim
drive and brake assembly was removed.
1) Using tools J1 (Install them to 3 places on
the periphery, equally spaced), secure
1. Place the assembly with the brake side down.
inner gear (6) and outer gear (7).
a Be sure to install tools J1 to protect
2. Carrier assembly
the floating seal before removing
1) Remove carrier assembly (1).
retainer (8).
a Install tools J1 to 3 places on the pe-
riphery, equally spaced.
2) Remove the mounting bolts, retainer (8),
and shim.
30 HM400-2
50 Disassembly and assembly SEN01446-00
4. Ring gear
Remove ring gear (9).
7. Brake assembly
1) Remove brake assembly (17) from shaft
(16).
a Make match marks in advance.
HM400-2 31
SEN01446-00 50 Disassembly and assembly
2) Disassemble the brake assembly accord- 2> Remove seal rings (21) and (22)
ing to the following procedure from cylinder (19) and piston (20).
1] Remove tools J1.
32 HM400-2
50 Disassembly and assembly SEN01446-00
8. Hub (Inner gear) and outer gear 3) Remove floating seal (30a) from floating
1) Remove outer gear (27) from hub (inner seal and cage assembly (29).
gear) (26).
HM400-2 33
SEN01446-00 50 Disassembly and assembly
34 HM400-2
50 Disassembly and assembly SEN01446-00
3) Install cover (32) to outer gear (31). 6) Install floating seal and cage assembly
(29) to hub (internal gear) (28).
HM400-2 35
SEN01446-00 50 Disassembly and assembly
3. Brake assembly
1) Install disc (25), plate (24), and damper
(end plate) (23).
a When installing the plate, match the 6
cuts on its periphery.
36 HM400-2
50 Disassembly and assembly SEN01446-00
HM400-2 37
SEN01446-00 50 Disassembly and assembly
38 HM400-2
50 Disassembly and assembly SEN01446-00
8. Carrier assembly
1) Assemble the carrier assembly according
to the following procedure.
1] Install bearing (5) and planetary gear
(4).
2] Install shaft (2).
a Take care not to lose ball (3).
HM400-2 39
SEN01446-00 50 Disassembly and assembly
2. Jacking up frame
1) Jack up the rear frame and support it on
stand [1], etc.
2) Using jacks [2] and [3], raise the center
5. Drive shaft between center differential and
axle and rear axle.
rear differential
Remove the guard and sling off drive shaft (8)
between the center differential and rear differ-
ential. [*2]
3. Center wheels
Sling both center wheels temporarily, then
remove the mounting bolts and center wheels
(1). [*1]
6. Drive shaft between hitch frame and center
4 Center wheel assembly: 800kg 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. [*3]
4 Drive shaft between hitch frame and
center differential:85 kg
40 HM400-2
50 Disassembly and assembly SEN01446-00
[*2]
a 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.
2 Mounting bolt of drive shaft between center
differential and rear differential:
Adhesive (LT-2)
3 Mounting bolt of drive shaft between center
differential and rear differential:
98 – 123 Nm {10 – 12.5 kgm}
9. Center axle and arm assembly [Target: 113 Nm {11.5 kgm}]
1) Sling center axle and arm assembly (12)
temporarily. [*3]
a When installing the lateral rod, match tap hole
(a) to the center line of bearing (15) as shown
in Fig.
HM400-2 41
SEN01446-00 50 Disassembly and assembly
[*4]
a 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 suspen-
sion cylinder pins is 574 mm (Clearance (Z)
between the rear axle top and rear frame bot-
tom is 130 mm at this time).
42 HM400-2
50 Disassembly and assembly SEN01446-00
2. Jacking up frame
1) Jack up the rear frame and support it on
stand [1], etc.
2) Jack up the center axle and rear axle with
5. Drive shaft between center differential and
jacks [2] and [3].
rear differential
Remove the guard and sling off drive shaft (8)
between the center differential and rear differ-
ential. [*2]
3. Rear wheels
Sling both rear wheels temporarily, then
remove the mounting bolts and rear wheels
(1). [*1]
6. Lateral rod
4 Rear wheel assembly: 800 kg Remove lateral rod (9). [*3]
4 Lateral rod: 60 kg
HM400-2 43
SEN01446-00 50 Disassembly and assembly
44 HM400-2
50 Disassembly and assembly SEN01446-00
Installation [*4]
a Install the rear axle and arm assembly so that
q Carry out installation in the reverse order to re- distance (Y) between the rear frame top and
moval. equalizer bar spring top will be 201 mm when
distance (X) between the rear suspension cyl-
[*1] inder pins is 574 mm (Clearance (Z) between
3 Rear wheel mounting bolt: the rear axle top and rear frame bottom is 130
824 – 1,030 Nm {84 – 105 kgm} mm at this time).
[Target: 926 Nm {94.5 kgm}]
[*2]
a 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.
2 Mounting bolt of drive shaft between center
differential and rear differential:
Adhesive (LT-2)
3 Mounting bolt of drive shaft between center
differential and rear differential:
98 – 123 Nm {10 – 12.5 kgm}
[Target: 113 Nm {11.5 kgm}]
HM400-2 45
SEN01447-00
HM400-2
HM400-2 1
SEN01447-00 50 Disassembly and assembly
1. Jacking up
1) Jack up the front (sub) frame and support
it on stand [1], etc.
2) Using jack [2], raise the front axle support.
2. Left fender
Lift of left fender (1).
2 HM400-2
50 Disassembly and assembly SEN01447-00
2. Bracket
Remove bracket (2).
HM400-2 3
SEN01447-00 50 Disassembly and assembly
[*2]
a Adjust the suspension cylinder length. For de- 2) Sling the hoist cylinder temporarily and
tails, see "Testing and adjusting", "Testing and bring it down at a right angle to vehicle
adjusting suspension cylinder". body.
k Pull the hoist cylinder toward in-
side of the vehicle body in ad-
vance. (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.)
4 HM400-2
50 Disassembly and assembly SEN01447-00
3) Remove rod pin (3) and hoist cylinder (4). 9. Using forcing screw [1], remove bushing (11).
[*2]
4 Hoist cylinder: 270 kg
HM400-2 5
SEN01447-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to re-
moval.
[*1]
Refill the rear suspension cylinder with nitro-
gen gas. For details, see "Testing and adjust-
ing suspension cylinder".
[*2]
3 Rod pin: 157 – 196 Nm {16 – 20 kgm}
[*3]
a When installing the plate, measure the dis-
tance between the vehicle body and equalizer
bar and adjust the difference between dis-
tances (a) and (b) and between (c) and (d) will
be 2 mm respectively.
3 Plate
Diameter of thread: 24 mm:
824 – 1,030 Nm {84 – 105 kgm}
Diameter of thread: 14 mm:
157 – 196 Nm {16 – 20 kgm}
a 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 cyl-
inder pins is 574 mm (Clearance (Z) between
the rear axle top and rear frame bottom is 130
mm at this time).
6 HM400-2
50 Disassembly and assembly SEN01447-00
2. Left fender
Lift off left fender (1).
3. Front wheels
Sling the front wheels (2) temporarily, then
remove the mounting bolts and front wheels
(2). [*1]
4 Front wheel assembly: 800 kg
HM400-2 7
SEN01447-00 50 Disassembly and assembly
8 HM400-2
50 Disassembly and assembly SEN01447-00
HM400-2 9
SEN01447-00 50 Disassembly and assembly
10 HM400-2
50 Disassembly and assembly SEN01447-00
9. Hinge pins
1) 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 [3] and [4] to center the hinge pins.
3) Pull up out lower hinge pin (23) with a parts around the pins until the rear
jack. frame of the front operator's cab sec-
tion is separated from the hitch frame
k 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.
k 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.
HM400-2 11
SEN01447-00 50 Disassembly and assembly
12 HM400-2
50 Disassembly and assembly SEN01447-00
Installation
q Carry out installation in the reverse order to re-
moval
[*1]
a Bleed air from the brake circuit. For details,
see "Testing and adjusting", "Bleeding air from
brake circuit".
[*2]
a Test the wear of the brake pad and adjust the
brake pad clearance. For details, see "Testing
and adjusting", "Testing wear of parking brake
pad".
[*7]
[*3] a Procedure for adjusting bearing of oscillation
a When installing the drive shaft, check that the section
key way of the spider cap is matched to that of 1) Measure thickness (t) of end retainer (25)
the mating yoke and tighten the bolts. at 2 places (equally spaced on the periph-
2 Mounting bolt of drive shaft between hitch
ery).
frame and center differential: 2) Tighten mounting bolts (30) 3 pieces to
Adhesive (LT-2) the following torque without inserting shim
3 Mounting bolt of drive shaft between hitch
(29).
3 Mounting bolt: 68.6 Nm {7 kgm}
frame and center differential:
157 – 198 Nm {16 – 20 kgm} 3) Under this condition, measure dimension
[Target: 177 Nm {18 kgm}] (d) with a micrometer.
4) Rotate hitch frame (31) by 5 – 6 turns,
[*4] then repeat steps 2) and 3) above.
2 Coupling spline: LM-P a Repeat steps 2) – 4) above until
2 Coupling bolt: Adhesive (LT-2) dimension (d) is stabilized.
3 Coupling bolt: 5) Combine shims so that difference (e) of
824 – 1,030 Nm {84.0 – 105.0 kgm} the measured values (e) = (d – t) will be 0
– 0.15 mm.
[*5] 6) After finishing the above adjustment, tight-
a When installing the drive shaft, check that the en all mounting bolts (30) to the following
key way of the spider cap is matched to that of torque.
3 Mounting bolt:
the mating yoke and tighten the bolts.
2 Mounting bolt of drive shaft between trans-
385 Nm (Target) {39.25 kgm} (Target)
mission and hitch frame:
Adhesive (LT-2)
3 Mounting bolt of drive shaft between trans-
mission and hitch frame:
157 – 198 Nm {16 – 20 kgm}
[Target: 177 Nm {18 kgm}]
[*6]
a When installing rear seal (27) to rear retainer
(28), use push tool [6] matched to the diameter
of the seal.
HM400-2 13
SEN01447-00 50 Disassembly and assembly
2. Rear retainer
1) Using forcing screw [1], remove retainer
assembly (3).
14 HM400-2
50 Disassembly and assembly SEN01447-00
HM400-2 15
SEN01447-00 50 Disassembly and assembly
5. Coupling
Install coupling (2) and coupling holder (1).
2 Coupling spline: LM-P
3 Coupling bolt:
824 – 1,030 Nm {84.0 – 105.0 kgm}
16 HM400-2
50 Disassembly and assembly SEN01447-00
Removal and installation of body 5. Remove body hinge pins (3) on both sides. [*2]
assembly 1
Removal
1. Remove both hoist cylinder rod pins (1). [*1]
a Sling the bottom of the hoist cylinder tem-
porarily.
a 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.
k if rod pin (1) is removed, the hoist cylinder
falls outward. Accordingly, be sure to pull
the cylinder toward inside of the vehicle
6. Lift off body assembly (4). [*3]
body in advance.
4 Body assembly: 4,450 kg
HM400-2 17
SEN01447-00 50 Disassembly and assembly
[*3]
q Adjustment ob body mount shims
1) Install spacer (5) 58 mm high tote end of
body (4). (1 place on each side)
2) Measure clearance (a) between the center
of the mounting part of bottom mount (6)
and frame top (7).
a Measure at (A), (B), and (C) on both
side, 6 places in total.
18 HM400-2
50 Disassembly and assembly SEN01447-00
HM400-2 19
SEN01448-00
HM400-2
HM400-2 1
SEN01448-00 50 Disassembly and assembly
Hydraulic system 1
Disassembly and assembly of steering valve 1
Component parts
2 HM400-2
50 Disassembly and assembly SEN01448-00
Parts list
Part No. Part name Q‘ty Remarks
1 Screw 6
2 Retainer screw assembly 1
3 End cap 1
4 Gerotor 1
5 Spacer 1
6 Spacer (1)
7 Spacer plate 1
8 Drive 1
9 Housing 1
10 Sleeve 1
11 Spool 1
12 Pin 1
Centering spring 6 For standard input torque specification
13
Centering spring 4 For low input torque specification
14 Flat spring (2) Only for low input torque specification
15 Race bearing 1
16 Thrust needle 1
17 O-ring 1
18 Oil seal 1 X-ring or Teflon seal
19 Dust seal 1
20 Retaining ring 1
21 Seal gland bushing 1
22 O-ring 2 Part No.: 5776
23 O-ring 1 Part No.: BA0098A
24 Inlet check valve sub assembly 1 (Cannot be disassembled)
25 Valve seat 1 (Cannot be disassembled)
26 Poppet 1
27 Spring 1
28 Plug 1
29 O-ring 1
30 Retainer plug 2
31 Spring 2
32 Ball 2
33 Valve seat 2 (Cannot be disassembled)
34 Ball 2
35 Ball holder 2
36 Spring 2
37 Plug 2
38 O-ring 2
39 Adapter screw 1
40 Ball 1
41 Name plate 1
42 Rivet 2
HM400-2 3
SEN01448-00 50 Disassembly and assembly
1. Put end cap (3) at the top, fit side face of hous-
ing between copper sheets in vice [8], and be
careful not to tighten vice too strongly.
4 HM400-2
50 Disassembly and assembly SEN01448-00
6. Set housing updise down, remove 2 springs a When remove the seal, be careful not to
(31), 2 retainer lugs (30), and 2 balls (32). damage the seal gland bushing.
a Be careful not to drop or lose the parts.
HM400-2 5
SEN01448-00 50 Disassembly and assembly
11. Push out spool inside sleeve slightly, and 14. Disassembly of overlord relief valve
remove centering spring (13) carefully by hand Using hexagonal wrench (width across flats: 3/
from spool. 16 inch), remove plug (37) 2 places. Remove
O-ring (38) from plug. Using tweezers, remove
2 springs (36), 2 ball holders (35), and 2 balls
(34).
a The valve seat is stuck to the housing and
cannot be removed.
6 HM400-2
50 Disassembly and assembly SEN01448-00
HM400-2 7
SEN01448-00 50 Disassembly and assembly
4. Place housing on clean flat surface, then a The diagram below is the standard seal
assemble O-ring (17). specification drawing.
Assemble 2 race bearings (15) and thrust nee-
dle (16). Always insert thrust needle between
race bearings.
8 HM400-2
50 Disassembly and assembly SEN01448-00
HM400-2 9
SEN01448-00 50 Disassembly and assembly
11. Of the 7 bolt holes in the end face of the hous- 14. Assemble O-ring (22) to Gerotor (4).
ing, insert ball (40) in the holes shown in the
drawing. Assemble adapter screw (39) in holes
in same drawing.
10 HM400-2
50 Disassembly and assembly SEN01448-00
16. Assemble spacer (5) to spline Gerotor star. 17. Order for tightening end cap mounting screws
a Do not assemble spacers to 51 cc/rev and is as shown in diagram below.
69 cc/rev discharge capacity Orbit-rolls.
Asseble 2 spacers to 184 cc/rev discharge
capacity orbit-roll.
Assemble O-ring (22) to end cap (3), set
on top of Gerotor, then align bolt holes.
Coat 6 screws (1) and thread of retainer
screw assembly (2) with oil, then assem-
ble to end cap.
Install retainer screw assemblies to bolt
holes where adapter screws have already
been assembled. 14.7 Nm {1.5 kgm}, then
tighten in order to following torque.
Discharge Discharge
Spacer
capacity capacity
thickness (mm)
symbol (cc/rev)
A 51 —
B 69 —
C 96 3.6
D 120 6.1
E 159 12.2
12.2
G 184
3.6
K 230 22.0
M 277 24.4
P 369 41.1
S 461 53.7
T 553 66.4
U 737 91.8
HM400-2 11
SEN01448-00 50 Disassembly and assembly
Removal and installation of flow 3) Remove the mounting bolts of pipe (7) of
amplifier valve assembly 1 priority circuit (EF) (the circuit to the port P
of the hoist valve) and keep pipe (7) away
Removal from the steering valve.
a Loosen the mounting bolts of port P
1. Tilting up operator’s cab of the hoist valve.
Bring the hood down forward (and fix it) and tilt
up operator’s cab (1) and support it with the
safety bar.
k Check that the operator’s cab is sup-
ported securely with the safety bar.
Installation
q Carry out installation in the reverse order to
removal.
12 HM400-2
50 Disassembly and assembly SEN01448-00
Removal and installation of hoist a Loosen the rear tube clamp and move
valve assembly 1 the tubes toward the hydraulic tank.
Removal
1. Drain the hydraulic oil.
2. Left fender
Lift off left fender (1).
5. Hoist valve
Remove hoist valve assembly (12).
4 Hoist valve assembly: 65 kg
3. Flow-amplifier valve
Remove the flow-amplifier valve assembly. For
details, see "Removal and installation of steer-
ing valve assembly".
[*1]
3 Check valve mounting bolt (Hexagon socket
head bolt):
14.7 – 24.5 Nm {1.5 – 2.5 kgm}
(Target: 24.5 Nm {2.5 kgm})
HM400-2 13
SEN01448-00 50 Disassembly and assembly
14 HM400-2
50 Disassembly and assembly SEN01448-00
Assembly
q Clean the all parts carefully and remove burrs. 3. Housing assembly
q Apply engine oil to the sliding parts before 1) Install retainer (14), valve (13), and spring
installing. (12) to housing (2) and tighten sleeve (11).
2) Install seat (10) and holder (9) and tighten
1. Body assembly nut (3).
1) Install valve (31), spring (30), and seat 3) Install poppet (8), spring (7), and retainer
(29) to body (1). (6) and tighten nut (5) and screw (4).
2) Install plug (28) and spool (27) to body (1). 4) Install body (1) to housing (2).
2 Mating faces of housing and body:
2. Spring case assembly Sealant (LOCTITE #572 or 575
1) Install spring (26), retainer (25), and or Sealend #242)
springs (24) and (23) to spring case (19), 3 Housing
then install flange (22). Diameter of thread: 12 mm:
2) Install plug (21). 110.3 ± 12.6 Nm {11.25 ± 1.25 kgm}
3) Install retainer (20) to body (1), then install Diameter of thread: 14 mm:
spring case (19). 176.5 ± 19.6 Nm {18 ± 2 kgm}
4) Install retainer (18) and springs (17) and
(16) to body (1), then install spring case
(15).
HM400-2 15
SEN01448-00 50 Disassembly and assembly
New/Remodel
cage assembly (1).
Necessity
Sym-
Part No. Part name 3) Remove check valve (1b).
Sketch
bol
a Put an oil pan etc. under the cylinder to
Q'ty
receive the oil.
Cylinder repair
790-502-1003 t 1
1 stand
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench assembly t 1
790-102-1480 Wrench assembly t 1
3
790-102-4310 Pin t 2
790-720-1000 Expander t 1
796-720-1670 Ring t 1
4 07281-01279 Clamp t 1
796-720-1680 Ring t 1
07281-01289 Clamp t 1
U 790-201-1702 Push tool kit t 1 4) Set cylinder assembly (2) to tool U1.
790-101-5021 • Grip 1 5) Loosen the cylinder head nut and remove
01010-50816 • Bolt 1 cylinder head assembly (3) with tool U2.
5
790-201-1811 • Push tool 1
790-201-1881 • Push tool 1
790-201-1841 • Push tool 1
790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6
790-201-1620 • Plate 1
790-201-1690 • Plate 1
790-201-1650 • Plate 1
16 HM400-2
50 Disassembly and assembly SEN01448-00
8) Disassemble the piston rod assembly 3] Using tool U3, remove piston assem-
according to the following procedure. bly (6).
1] Set piston rod assembly (4) to tool q When not using tool U3, loosen
U1. the piston assembly by using the
drilled holes (DH) (ø10: 4 places).
HM400-2 17
SEN01448-00 50 Disassembly and assembly
18 HM400-2
50 Disassembly and assembly SEN01448-00
3. Assembly of piston assembly 2) Set plunger (11) to the piston rod. Install
1) Using tool U4, expand piston ring (13). 11 balls (10) and secure them with cap (9).
a Set the piston ring to tool U4 and give a Check that there is some play at the
the handle 8 – 10 turns to expand the plunger end.
piston ring.
2) Set tool U4 and contract piston ring (13).
HM400-2 19
SEN01448-00 50 Disassembly and assembly
7) Remove piston rod assembly (2) form tool 4) Install seal cage (1) and tighten bolts (1a).
U1. 5) Install check valve (1b).
3 Check valve:
83.4 – 147 Nm {8.5 – 10.5 kgm}
20 HM400-2
50 Disassembly and assembly SEN01448-00
New/Remodel
Necessity
Sym-
Part No. Part name 2. Using tool U2, remove crown (1) from No. 1
Sketch
bol
cylinder (2).
Q'ty
a After loosening the crown, remove the
790-502-1003
Cylinder repair
t 1
grease nipple from the rod head, then pull
1 stand out the crown.
790-101-1102 Hydraulic pump t 1
2 790-102-3802 Wrench assembly t 1
790-720-1000 Expander t 1
796-720-1670 Ring t 1
4 07281-01279 Clamp t 1
796-720-1680 Ring t 1
07281-01289 Clamp t 1
790-201-1702 Push tool kit t 1
U 790-101-5021 • Grip 1
01010-50816 • Bolt 1
5
790-201-1811 • Push tool 1
790-201-1881 • Push tool 1 3. Remove No. 2 cylinder and rod assembly (20)
from No. 1 cylinder (2).
790-201-1841 • Push tool 1
790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6
790-201-1620 • Plate 1
790-201-1690 • Plate 1
790-201-1650 • Plate 1
4. Remove bolt (3), then lift off rod (5) from No. 2
cylinder (4).
HM400-2 21
SEN01448-00 50 Disassembly and assembly
5. Remove cylinder head assembly (6) from No. 9. Disassembly of piston assembly
2 cylinder (4). Remove piston ring (14) and wear ring (15)
from piston assembly (13).
6. Remove wear ring (7).
22 HM400-2
50 Disassembly and assembly SEN01448-00
HM400-2 23
SEN01448-00 50 Disassembly and assembly
8. Install wear ring (7) to No. 2 cylinder (4). 3) Using tool U6 install dust seal (9).
9. Assembly of cylinder head assembly 10. Assemble cylinder head (6) to No. 2 cylinder
1) Using tool U5, press fit bushing (11). (4).
24 HM400-2
50 Disassembly and assembly SEN01448-00
HM400-2 25
SEN01449-00
HM400-2
HM400-2 1
SEN01449-00 50 Disassembly and assembly
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of the 2 clips (2) of headrest stay (1) on
both sides.
2 HM400-2
50 Disassembly and assembly SEN01449-00
HM400-2 3
SEN01449-00 50 Disassembly and assembly
4) Apply force (E) to the right side of seat- 2) Push cushion stopper wire (9) down with
back (4) in the direction of the arrow. screwdriver [1], etc.
5) Applying the force to seatback (4), pull its 3) Pull out seat cushion (8) forward and
right side up. remove it.
6) Slide seatback (4) sideway and remove it.
4. Armrest
3. Seat cushion q The procedure for disassembling right-
1) Push cushion adjuster lever (7) inward hand armrest (10) is shown below.
and slide seat cushion (8) to the front end. (Disassemble left-hand armrest (11) simi-
larly.)
4 HM400-2
50 Disassembly and assembly SEN01449-00
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. a There are 2 position adjustment wash-
a Use a flat-head screwdriver, etc. to ers (16) installed to each bolt between
remove the cap. the armrest and seatback. Take care
2) Loosen armrest hinge mounting bolt (13). not lose them.
HM400-2 5
SEN01449-00 50 Disassembly and assembly
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part;2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
6 HM400-2
50 Disassembly and assembly SEN01449-00
HM400-2 7
SEN01449-00 50 Disassembly and assembly
3) Set rails (28) to the rear end and install 1 2) Install 3 metallic suspension cover clips
lock washer (30) and 1 hexagon socket (24).
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
8 HM400-2
50 Disassembly and assembly SEN01449-00
5) Install plastic plate (18) to the rear. 2) Tighten lower mounting bolt (15A) lightly
6) Install right-hand hinge cover (17). and turn armrest (10) by 180°.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
3. Armrest
q The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) simi-
larly.)
HM400-2 9
SEN01449-00 50 Disassembly and assembly
10 HM400-2
50 Disassembly and assembly SEN01449-00
6. Headrest
Insert headrest (3) in seatback (4).
a Check that 2 clips (2) on both sides
are locked securely.
HM400-2 11
SEN01449-00 50 Disassembly and assembly
New/Remodel
securely.
a Keep slinging operator's cab (3) (tem-
Necessity
Sym-
Part No. Part name
porarily).
Sketch
bol
Q'ty
799-703-1200 Service tool kit t 1
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 1 799-703-1111 t 1
(220V)
Vacuum pump
799-703-1121 t 1
(240V)
799-703-1401 Gas leak detecter t 1
Removal
k Stop the machine on a level ground, apply 2. Heater hose
the parking brake, and then lock the tires 1) Disconnect heater hose (4).
with chocks. a Check the connecting parts of the
k Set the lock bar to the frame. heater hose.
k Disconnect the cable from the negative (–) a Prepare an oil receiver.
terminal of the battery. 2) Remove covers (5) and (6).
k If the radiator coolant temperature is high,
wait until it lowers to avoid scalding your-
self before disconnecting the heater hose.
k Collect the air conditioner refrigerant
(R134a) in advance.
k If refrigerant (R134a) gets in your eyes, you
may lose your sight. Accordingly, when
collecting or adding it, you must be quali-
fied for handling the refrigerant and put on
protective goggles.
12 HM400-2
50 Disassembly and assembly SEN01449-00
3. Return the operator's cab tilted up to the hori- 8. Remove frame (13).
zontal position.
HM400-2 13
SEN01449-00 50 Disassembly and assembly
11. Disconnect connectors BRC1 (16), BRC2 (17) 14. Remove controller mounting frame (23).
and BRC3 (18) from retarder controller (15).
13. Disconnect connectors ATC1 (20), ATC2 (21) 17. Remove duct (26).
and ATC3 (22) from transmission controller
(19).
14 HM400-2
50 Disassembly and assembly SEN01449-00
18. Remove duct (27). 23. Remove external air filter box (34).
19. Disconnect hose (28). 24. Remove rear mounting bolts (35) and (36) of
air conditioner unit assembly (37).
20. Remove mounting bolt (29) and disconnect
hose assembly (30).
HM400-2 15
SEN01449-00 50 Disassembly and assembly
16 HM400-2
50 Disassembly and assembly SEN01449-00
HM400-2 17
SEN01450-00
HM400-2
HM400-2 1
SEN01450-00 50 Disassembly and assembly
2 HM400-2
50 Disassembly and assembly SEN01450-00
Installation
q Carry out installation in the reverse order to
removal.
HM400-2 3
SEN01450-00 50 Disassembly and assembly
4 HM400-2
50 Disassembly and assembly SEN01450-00
Installation
q Carry out installation in the reverse order to
removal.
HM400-2 5
SEN01450-00 50 Disassembly and assembly
Removal and installation of 2. Remove power train filter (3) from crossbar (4).
engine controller assembly 1
Removal
k Stop the machine on a level ground, apply
the parking brake, and then lock the tires
with chocks.
k Set the lock bar to the frame.
k Disconnect the cable from the negative (–)
terminal of the battery.
6 HM400-2
50 Disassembly and assembly SEN01450-00
HM400-2 7
SEN00533-00
HM400-2
HM400-2 1
Hydraulic circuit diagram SEN00533-00
HM400-2 3
90 Diagrams and drawings SEN00533-00
HM400-2 5
SEN00533-00 90 Diagrams and drawings
6 HM400-2
90 Diagrams and drawings SEN00533-00
HM400-2 7
SEN00533-00 90 Diagrams and drawings
8 HM400-2
SEN00533-00 90 Diagrams and drawings
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (02)
10 HM400-2
SEN00534-01
HM400-2
HM400-2 1
SEN00534-01 90 Diagrams and drawings
2 HM400-2
90 Diagrams and drawings SEN00534-01
HM400-2 19
SEN00534-01 90 Diagrams and drawings
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 05-06 (02)
20 HM400-2
Electrical circuit diagram 1 SEN00534-01
HM400-2 3
Electrical circuit diagram for inside cab (2/4) 1 SEN00534-01
HM400-2 5
Electrical circuit diagram for inside cab (3/4) 1 SEN00534-01
HM400-2 7
Electrical circuit diagram for inside cab (4/4) 1 SEN00534-01
HM400-2 9
Electrical circuit diagram for outside cab (1/3) 1 SEN00534-01
HM400-2 11
Electrical circuit diagram for outside cab (2/3) 1 SEN00534-01
HM400-2 13
Electrical circuit diagram for outside cab (3/3) 1 SEN00534-01
HM400-2 15
Connectors table and arrangement drawing
Connectors table and arrangement drawing HM400-2
Connector No. Type of Number Location Address Connector No. Type of Number Location Address Connector No. Type of Number Location Address Connector No. Type of Number Location Address
connector of pins connector of pins connector of pins connector of pins
41 Terminal 1 Backup buzzer L-9 CH1 M 8 Machine monitor mode selector switch 1 O-2 EGR DT 2 EGR valve solenoid AC-6 PWR 1×2 Power window motor (right) (if equipped) E-8
49 Terminal 1 Backup buzzer L-9 CH2 M 8 Machine monitor mode selector switch 2 O-2 EM 6 Emergency steering timer Z-8 R01 Relay 5 Engine start relay Z-2
50 Terminal 1 Battery relay L-1 CHK1 X 1 KOMTRAX set switch 1 R-7 ENG — 60 Engine controller AH-4 R02 Relay 5 Parking brake relay Z-2
53 Terminal 1 Battery relay K-1 CHK2 X 1 KOMTRAX set switch 2 Q-7 ER Terminal 3 Chassis ground (battery room) E-1 R03 Relay 5 Dust indicator relay Z-2
54 Terminal 2 Emergency steering relay L-3 CJA DT2 6 Joint connector ER Terminal 1 Chassis ground (front frame) F-1,H-2,I-3 R04 Relay 6 Brake lamp relay Z-1
55 Terminal 1 Emergency steering relay M-3 CJB DT2 8 Joint connector B-8 ER Terminal 1 Chassis ground (rear frame) M-5 R05 Relay 6 Backup lamp and buzzer relay Z-1
56 Terminal 1 Emergency steering relay M-3 CJE DT2 8 Joint connector A-8 ER1 Terminal 1 Chassis ground (in cab) E-8 R06 Relay 6 Fog lamp relay (if equipped) Z-2
57 Terminal 2 Emergency steering relay M-3 CJE4 DT2B 6 Joint connector AG-3 ER1 Terminal 1 Chassis ground (rear frame) G-9 R07 Relay 5 Auto preheat relay Z-2
58 Terminal 2 Emergency steering relay K-2 CJF DT2 8 Joint connector B-9 ER2 Terminal 1 Chassis ground (in cab) Z-7 R08 Relay 5 Yellow rotary lamp relay (if equipped) Z-2
59 Terminal 1 Emergency steering relay K-2 CJG DT2 8 Joint connector B-8 ER3 Terminal 1 Chassis ground (in cab) Q-2 R09 Relay 6 Working lamp (front) relay Z-1
60 Terminal 1 Emergency steering relay K-2 CJK DT2 6 Joint connector M-8 FE1 DT2 2 Transmission differential speed sensor I-2 R10 Relay 5 Horn relay Z-1
61 Terminal 2 Emergency steering relay M-3 CJL DT2 8 Joint connector N-2 FLS 4 Flasher V-1 R11 Relay 6 Side lamp relay (if equipped) Z-2
62 Terminal 1 Circuit breaker (80 A) N-2 CJP DT2 6 Joint connector C-2 FOG M 6 Fog lamp (if equipped) P-1 R12 Relay 6 Hazard relay 1 Z-2
63 Terminal 1 Circuit breaker (80 A) N-2 CJR DT2 8 Joint connector A-9 FWL 2 Front working lamp (left) F-9 R13 Relay 5 Hazard relay 2 Z-1
64 Terminal 1 Circuit breaker (80 A) N-2 CJS DT2 8 Joint connector A-8 FWM 2 Front window washer motor (front) A-4 R14 Relay 5 Headlamp relay Z-1
65 Terminal 1 Circuit breaker (80 A) N-2 CJT DT2 8 Joint connector A-8 FWR 2 Front working lamp (right) D-7 R15 Relay 5 Headlamp selector relay Z-1
66 Terminal 2 Battery relay K-2 CJU DT2 6 Joint connector M-7 G SUMITOMO 3 Engine Bkup speed sensor AE-2 R16 Relay 6 Headlamp Hi relay AA-2
69 Terminal 3 Battery relay K-2 CJY DT2 8 Joint connector A-3 G1 Terminal 1 Chassis ground (front frame) A-3 R17 Relay 5 Parking brake safety relay AA-2
70 Terminal 2 Emergency steering relay L-3 CJZ DT2 6 Joint connector M-8 GS Terminal 2 Chassis ground (engine) AH-6 R21 Relay 5 Rear glass heater relay Z-1
71 Terminal 2 Emergency steering relay L-3 CM DT2 8 Lamp/Turn signal/Dimmer switch S-1 HAZ 6 Hazard lamp switch R-7 R25 11 Power window relay Z-8
72 Terminal 1 Emergency steering relay L-4 CM DT2 2 Intermediate connector E-1 HEAT M 6 Rear glass heater (if equipped) O-2 R33 6 Parking brake switch W-1
73 Terminal 2 Emergency steering relay L-4 CN1 DT 2 Injector #1 AC-6 HEAT1 1 Rear glass heater (if equipped) E-8 R34 7 Power window switch (right) (if equipped) V-9
74 Terminal 2 Emergency steering relay K-3 CN2 DT 2 Injector #2 AD-8 HEAT2 1 Rear glass heater (if equipped) I-9 R35 7 Power window switch (left) V-9
75 Terminal 2 Emergency steering relay K-3 CN3 DT 2 Injector #3 AF-8 HN 1 Horn switch R-2 R38 Relay 5 Engine cut-off relay Z-1
76 Terminal 1 Emergency steering relay K-3 CN3 DT2 2 Transmission input shaft speed sensor AI-7 HSL DT2 4 Damper lever potentiometer Y-2 RAD 9 Cassette radio Q-3
77 Terminal 2 Emergency steering relay K-3 CN4 DT 2 Injector #4 AG-8 J01 HD 9 Intermediate connector C-8 RE1 2 Resistor S-1
78 DT2 2 Starting motor AD-8 CN4 DT2 2 Transmission intermediate shaft speed sensor AN-4 J02 HD 31 Intermediate connector D-8 RES DT 2 Service connector AG-8
80 Terminal 1 Alternator (terminal R) AC-5 CN5 DT 2 Injector #5 AG-7 J03 HD 31 Intermediate connector C-9 RL 2 Room lamp E-8
81 Terminal 1 Circuit breaker (30 A) L-1 CN5 DT2 2 Transmission output shaft speed sensor AN-5 J04 HD 31 Intermediate connector D-9 RL2 2 Room lamp 2 G-9
82 Terminal 2 Circuit breaker (30 A) N-2 CN6 DT 2 Injector #6 AG-7 J05 HD 14 Intermediate connector D-9 RTL DT2 6 Retarder lever potentiometer S-2
83 Terminal 1 Circuit breaker (30 A) L-1 CN6 DT2 2 Lo clutch ECMV solenoid valve AM-8 J06 DT06 4 Intermediate connector Z-5 RWM 2 Window washer motor (rear) A-4
84 Terminal 1 Circuit breaker (30 A) M-1 CN7 DT2 2 Lo clutch ECMV fill switch AM-8 J08 HD 14 Intermediate connector C-9 SBP DT 4 Bypass valve lift sensor AE-8
86 DT1 2 Intermediate connector J-3 CN8 DT2 2 R clutch ECMV solenoid valve AM-8 J09 HD 31 Intermediate connector C-9 SBS ST2 2 Seat belt switch Y-2
94 Terminal 1 Chassis ground (rear frame) M-8 CN9 DT2 2 R clutch ECMV fill switch AM-8 J12 DT2 12 Intermediate connector J-3 SDE M 6 Side lamp switch (if equipped) P-2
DPC3B 12 Machine monitor S-7 CN10 DT2 2 Hi clutch ECMV solenoid valve AN-7 J13 DT2 12 Intermediate connector M-6 SEGR DT 4 EGR valve lift sensor AC-3
A1 1 Emergency escape switch Y-8 CN11 DT2 2 Hi clutch ECMV fill switch AN-7 J14 DT2 14 Intermediate connector K-4 SF1 DT2 12 Gearshift lever X-1
AC1 Air conditioner unit W-9 CN12 DT2 2 1st clutch ECMV solenoid valve AN-7 J15 DT2 14 Intermediate connector M-6 SF2 DT2 2 Gearshift lever X-1
AC2 AMP 8 Air conditioner control panel P-5 CN13 DT2 2 1st clutch ECMV fill switch AM-8 J18 DT2B 12 Intermediate connector F-1 SLL DT1 2 Side lamp (left) (if equipped) K-3
ACC 6 Retarder switch linked with accelerator Q-3 CN14 DT2 2 2nd clutch ECMV solenoid valve AL-8 J19 HD 9 Intermediate connector H-2 SLR 2 Side lamp (right) (if equipped) C-7
ACC Terminal 1 Starting switch Q-7 CN15 DT2 2 2nd clutch ECMV fill switch AL-9 J1939 DT 3 Service connector AE-8 SPARE X 4 Service power supply connector X-9
ACRD X 2 Air conditioner gas pressure switch C-2 CN16 DT2 2 3rd clutch ECMV solenoid valve AL-8 J2P DT 50 Engine controller E-1,AH-5 SPL 2 Speaker (left) H-9
AISS 6 AISS LOW switch Q-6 CN17 DT2 2 3rd clutch ECMV fill switch AL-8 J3P DT 4 Engine controller D-1,AH-3 SPR 2 Speaker (right) F-8
AS1 DT2 6 Accelerator pedal sensor R-2 CN18 DT2 2 Lockup clutch solenoid valve AK-9 JCA SWP 16 Joint connector X-9 ST1 Terminal 1 Emergency steering switch O-9
ASS DT2 2 Air suspension seat Z-5 CN20 DT2 2 Differential lockup solenoid valve AN-7 JCC SWP 16 Joint connector T-1 ST2 Terminal 1 Emergency steering switch O-8
ATC1 DRC 24 Transmission controller AB-7 CN22 DT2 3 Torque converter intermediate oil pressure sensor AI-8 JCD SWP 16 Joint connector T-1 ST3 Terminal 1 Emergency steering switch O-8
ATC2 DRC 40 Transmission controller AB-7 CN23 DT2 2 Torque converter oil temperature sensor AI-5 JCE SWP 16 Joint connector T-1 ST4 Terminal 1 Emergency steering switch P-9
ATC3 DRC 40 Transmission controller AA-8 CN24 DT2 2 Transmission oil temperature sensor AI-6 JM01 — 6 Junction wiring harness AH-5 T1 Terminal 1 Chassis ground (transmission) AN-6
ATC6 X 4 Service connector Y-9 CNS1 DT2 12 Intermediate connector Y-2 JM02 — 6 Junction wiring harness AH-4 T01 DT2 3 Dump selector valve L-4
B Terminal 1 Starting switch P-7 CNS2 DT2 12 Intermediate connector X-2 JM03 — 4 Junction wiring harness AH-3 T02 DT2 2 Dump EPC valve K-4
B06 DT2 2 Brake cooling oil control valve (rear) H-2 CNS3 DT2 12 Intermediate connector X-2 JM04 — 4 Junction wiring harness AG-3 T03 DT2 2 Transmission oil filter clogging switch E-8
B07 DT2 2 Brake cooling oil control valve (front) A-5 COMP DT2 2 Air conditioner compressor B-2 JM05 — 3 Junction wiring harness AH-5 T04 DT2 2 Steering oil temperature sensor M-5
B09 DT2 2 Intermediate connector I-3 D01 2 Diode P-4 JM06 — 3 Junction wiring harness AH-5 T10 DT2 3 Pitch angle sensor M-9
B14 DT2 2 Parking brake solenoid valve H-9 D02 2 Diode AB-1 JM07 — 4 Junction wiring harness AF-8 T14 DT2 3 Boom positioner sensor K-9
B15 DT2 2 Service brake oil pressure switch M-6 D03 2 Diode AB-1 JM08 — 6 Junction wiring harness AF-8 TC200 40 KOMTRAX terminal R-8
B16 DT2 2 Retarder oil pressure switch (front) M-6 D04 2 Diode AA-2 KAI 1 Yellow rotary lamp (if equipped) D-7 TCHET X 4 Heater and tachograph unit P-5
B17 DT2 2 Parking brake oil pressure switch M-7 D05 2 Diode AA-2 LKO DT2 2 Dump lever kick-out solenoid Z-3 TEL DT2 12 Intermediate connector P-8
B18 DT2 2 Retarder proportional pressure reducing valve (rear) M-7 D06 2 Diode AA-2 LS 3 Brightness control switch V-1 TFUEL PACKARD 2 Fuel temperature sensor AH-7
B19 DT2 2 Retarder proportional pressure reducing valve (front) H-9 D07 2 Diode P-5 M01 DT2 2 Coolant level switch H-2 TIM PACKARD 2 Charge temperature sensor AH-7
B21 DT2 2 Accumulator oil pressure switch (front) C-6 D08 2 Diode P-4 M02 DT2 2 Hydraulic oil level switch (if equipped) L-5 TWTR PACKARD 2 Engine coolant temperature sensor AG-8
B22 DT2 2 Accumulator oil pressure switch (rear) C-7 D09 2 Diode P-5 M03 DT2 2 Hydraulic oil filter clogging switch (if equipped) L-4 WFM 6 Wiper motor (front) U-1
B23 DT2 2 Retarder oil pressure switch (rear) I-9 D10 2 Diode AA-2 M05 DT2 2 Brake oil temperature sensor (rear) J-9 WFR 6 Wiper relay (front) U-1
B24 DT2 3 Accumulator oil pressure sensor (rear) C-7 D11 2 Diode AB-2 M05 DT2 2 Brake oil temperature sensor (center) K-9 WM 4 Intermediate connector P-4
B25 DT2 3 Accumulator oil pressure sensor (front) C-6 D12 2 Diode AB-2 M06 DT2 2 Fuel level sensor B-2 WPS DT2 12 Wiper and window washer switch S-1
B35 DT2 2 Differential lock solenoid valve (front) A-5 D13 2 Diode AB-2 M07 DT2 2 Brake oil temperature sensor (front) B-2 WRF M 6 Working lamp (front) switch P-1
B36 DT2 2 Differential lock solenoid valve (rear) M-7 D14 2 Diode AB-2 M08 DT2 2 Retarder oil filter clogging switch (if equipped) G-1 WRM 4 Wiper motor (rear) J-9
B39 DT2 2 Differential lock oil pressure switch (front) A-5 D15 2 Diode N-2 M11 DT2 2 Air cleaner clogging sensor A-4
B40 DT2 2 Differential lock oil pressure switch (Center) J-9 DEF 6 Interaxle differential lockup switch P-3 M-2 Terminal 1 Emergency steering motor G-1
B41 DT2 2 Differential lock oil pressure switch (rear) K-9 DEL 6 Right and left differential lockup switch Q-2 M-2 Terminal 1 Emergency steering motor G-1
BL47 2 Backup lamp M-8 DFS DT2 3 Right and left differential lockup pedal R-2 MON AMP 4 Rear view monitor P-6
BL4B 2 Backup lamp L-9 DL DT2 12 Service connector Y-8 NE FRAMATONE 3 Engine Ne speed sensor AH-5
BLS M 6 Yellow rotary lamp switch (if equipped) P-1 DPC1 20 Machine monitor T-8 OF 1 Engine oil filter clogging switch AH-7
BP DT 2 Bypass valve solenoid AD-8 DPC2A 18 Machine monitor S-8 OL DT1 2 Engine oil level switch AF-2
BR Terminal 1 Starting switch Q-6 DPC2B 12 Machine monitor S-7 OP7 M 1 Option selector connector U-1
BR Terminal 1 Starting motor terminal BR AD-8 DPC3A 18 Machine monitor S-7 P01 3 Headlamp (left) C-1
BRC1 DRC 24 Retarder controller AA-8 DPC4 12 Machine monitor T-8 P01 3 Headlamp (right) A-4
BRC2 DRC 40 Retarder controller AA-8 DPC6 8 Machine monitor R-7 P02 3 Front combination lamp (left) C-1
BRC3 DRC 40 Retarder controller Z-8 DPC7 X 4 Service connector R-7 P02 3 Front combination lamp (right) A-3
BRC6 X 4 Service connector Y-9 DSL 1 Door switch (left) F-9 P05 DT2 2 Turn lamp (left) M-5
BT1 — — Fuse box AA-4 DSR 1 Door switch (right) D-7 P05A DT2 2 Intermediate connector M-6
BT2 — — Fuse box AA-4 DT DT2 8 Intermediate connector E-1 P06 DT2 2 Turn lamp (right) D-7
BT3 — — Fuse box AA-4 DT1 DT2 6 Intermediate connector A-5 P07 2 Fog lamp (left) (if equipped) D-1
BT4 — — Fuse box AA-4 DT2 DT2 12 Intermediate connector B-6 P07 2 Fog lamp (right) (if equipped) A-3
BT-1A Terminal 1 Battery N-3 DT4 DT2 12 Intermediate connector J-3 P13 2 Horn valve (left) D-1
BT-1B Terminal 1 Battery M-3 DT5 DT2 8 Intermediate connector B-9 P13 2 Horn valve (right) A-4
BT-2A Terminal 1 Battery N-3 DT6 DT2 8 Intermediate connector B-9 P20 6 Rear combination lamp (left) M-9
BT-2B Terminal 1 Battery N-3 DT7 DT2 12 Intermediate connector Z-4 P21 6 Rear combination lamp (right) L-9
BT-3A Terminal 1 Battery (cold district specification) DT8 DT2 4 Intermediate connector Z-4 P22 2 Intermediate connector A-9
BT-3B Terminal 1 Battery (cold district specification) DT8 DT2 12 Intermediate connector D-1 PAMB FRAMATONE 3 Ambient pressure sensor AH-4
BT-4A Terminal 1 Battery (cold district specification) DT9 DT2 12 Intermediate connector A-3 PCV1 SUMITOMO 2 Supply pump #1 AD-2
BT-4B Terminal 1 Battery (cold district specification) E02 DT2 2 Emergency steering oil pressure switch I-2 PCV2 SUMITOMO 2 Supply pump #2 AE-2
BZ2 2 Alarm buzzer V-1 E1 Terminal 1 Alternator (terminal E) AC-6 PEVA CANNON 3 EGR inlet pressure sensor AC-7
C Terminal 1 Starting switch Q-7 E3 Terminal 1 Chassis ground (battery room) M-1 PFUEL AMP 3 Common rail pressure sensor AF-2
CAB1 SWP 12 Intermediate connector B-6 E3 Terminal 1 Chassis ground (rear frame) AD-3 PHO Terminal 1 Intake air heater relay M-1
CAB2 X 8 Intermediate connector B-6 E11 Terminal 1 Intake air heater relay M-1 PIM CANNON 4 Charge pressure sensor AH-6
CAN1 3 CAN terminal resistor AG-3 E12 Terminal 1 Intake air heater relay L-1 POIL CANNON 3 Engine oil pressure sensor AG-3
CAN2 DT2 3 CAN terminal resistor S-1 E-2 Terminal 1 Emergency steering motor G-1 PWL 1×2 Power window motor (left) M-5
CG 2 Cigarette lighter P-3 E-2 Terminal 1 Emergency steering motor G-1 PWM 6 Power mode selector switch P-3
SEN00534-01
HM400-2 17